Device for manufacturing green bricks and method therefor

Abstract

The invention relates to a device (2) for manufacturing green bricks (4) from a material, such as clay material, according to the invention and a method therefor. The device (2) according to the invention comprises: - a mould (8) for moulding the material; - a filling device (26) for introducing the material into the mould (8) in a filling direction (F); and - a pressing device (10) for pressing the material into a green brick in the mould (8) in a pressing direction (P); wherein the pressing direction (P) and the filling direction (F) lie at a filling angle (α) and wherein the mould (8) comprises one or more volume controllers (24) which are configured to control the quantity of material introduced into the mould (8).

Description

[0001] The invention relates to a device for manufacturing green bricks, for instance corner strips, for instance from a clay material. Said device is particularly a device for manufacturing corner strips. Such a device can additionally also relate to a device for manufacturing brick slips, bricks 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, wherein deformable material is generally introduced vertically into a mould and the material is pressed in substantially the same direction. The green brick moulded in the mould is then released so as to be dried and optionally fired, if necessary. Such devices are configured to manufacture green bricks provided with geometries wherein the dimension in filling and pressing direction is smaller than or substantially equal to the thickness of the green brick, wherein the thickness is the smallest dimension of the green brick. When the intended final product does not correspond hereto, for instance because the intended final product has a highly complex geometry, such as a corner strip, this product is generally formed from a manufactured basic green brick which is larger than the intended green brick in all dimensions. Such a basic green brick is provided here with a simpler geometry, for manufacture of which such devices are configured. The intended green brick is here for instance sawn and / or cut from the manufactured basic green brick, after which the excess material is discharged. The intended green brick can also be manufactured by attaching a number of partial green bricks provided with simpler geometries to each other, for instance with fastening means such as mechanical elements or adhesive.

[0003] A problem of such devices is that green bricks provided with geometries wherein the dimension in filling and pressing direction is substantially greater than the thickness of the green brick, such as corner strips, cannot be obtained directly from a mould, or at least not in the desired quality. This is caused by the aspect ratio effect. This is because, if the dimension in filling and pressing direction is substantially greater than the thickness of the green brick, the pressure cannot be distributed uniformly over the material. This may result in uneven compaction and inconsistencies in the final product. Additionally, a greater dimension in filling and pressing direction means more contact surface between the material and the walls of the mould. This increases friction, which may result in problems such as jamming or uneven flow of the material. The uneven pressure and increased friction may cause the material to deform during pressing. This may result in defects such as tears or undesirable deformations in the final product. In the case of a greater dimension in filling and pressing direction it can also be more difficult to allow air and other gases to escape from the mould, which can result in air inclusions and other defects. Additionally, such devices also experience problems when manufacturing green bricks with relatively small thicknesses, for instance in that the distribution of material over the mould causes problems.

[0004] The ways provided by the devices known in practice for nevertheless manufacturing the above stated green bricks are expensive, time-consuming and not energy efficient. In the first method stated above a whole basic green brick must be manufactured, while only a part of the green brick forms part of the intended final product. Firing of the basic green brick particularly takes a great deal of energy and time here. Additionally, subsequent cutting out of the intended green brick takes energy, time and likewise causes wear to the materials used therefor. There is also a great deal of excess material that cannot be reused, since this is material that has already been fired and / or hardened. The latter method stated above is also time-consuming, expensive and laborious, since different green bricks must be manufactured in order to obtain the intended final product. This necessitates different moulds, and thereby different production processes, after which attaching the partial green bricks to each other requires the necessary accuracy. In the latter method stated above a weak area will further always be present in the green brick because the green brick does not form one whole. This fracture between the partial green bricks may additionally also remain visible in the final product, which may be aesthetically unattractive.

[0005] 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.

[0006] This object is achieved with the device according to claim 1.

[0007] In the device according to the invention the pressing direction and the filling direction lie at a filling angle. Filling angle is understood to mean an angle between the pressing direction and the filling direction which is greater than 0°. In other words, the pressing direction and the filling direction are not parallel. By placing the pressing direction and the filling direction at a filling angle the device makes it possible to obtain the green bricks directly from a mould in the present invention. The device according to the invention is particularly configured to manufacture green bricks provided with geometries wherein the dimension in filling and pressing direction is greater than the thickness of the green brick, as is the case with corner strips.

[0008] In a currently preferred embodiment the material from which the green bricks are manufactured in the device according to the invention 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.

[0009] The mould in the device according to the invention is configured to mould the material into the desired shape. The mould can be a recess in a mould container and as such form one whole. It is however also possible to envisage the mould consisting of a plurality of components, optionally provided with simpler geometry, these together forming the mould in the device according to the invention. In a particular embodiment according to the invention the mould comprises a positive form, a negative form, a lower closing element for closing off the positive form and the negative form and an upper closing element for closing off the positive form and the negative form. In such an embodiment the mould is bounded by four parts, wherein the green brick is manufactured between a positive form and a negative form, both of these being closed off by a lower closing element and an upper closing element. It is also possible to envisage one or more other components of the device functioning as one or more of these components of the mould. Such an embodiment according to the invention has the advantage that the modularity of the mould is increased, making the mould and / or parts thereof easily replaceable.

[0010] The filling device in the device according to the invention is configured to introduce the material into the mould in a filling direction. Such a filling device preferably comprises a hopper, which is preferably funnel-shaped, provided with one or more openings and one or more outlets. The material to be moulded is introduced into the hopper via the one or more openings and is introduced into the mould at one or more locations via the one or more outlets. The one or more outlets are preferably substantially identical to the shape of the mould, this resulting in a uniform filling of material in the mould. In a particular embodiment according to the invention the filling device fills a plurality of moulds simultaneously.

[0011] In a currently preferred embodiment according to the invention the filling device is movable, such that the filling device can be moved onto and / or close to the mould in use and can be moved away from the mould when not in use. This provides the advantage that, when not in use, the filling device creates space around the mould for other components of the device, allowing the manufacturing process to be performed more compactly and simply.

[0012] In an alternative embodiment it is also possible for the mould to move toward the filling device and away from the filling device and / or for the mould and the filling device to move away from each other and toward each other.

[0013] The filling device is preferably filled with one type of material. It is however also possible to envisage the mould 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 a plurality of filling devices or a plurality of hoppers in a single filling device with a material with different properties each. Green bricks consisting of a plurality of layers can for instance be obtained by filling the mould 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.

[0014] The pressing device in the device according to the invention is configured to press the material into a green brick in the mould in a pressing direction, to compress the material and / or at least give it the desired shape. Such a pressing device preferably comprises one or more pressing elements which preferably fit close-fittingly in at least one part of the mould. The one or more pressing elements are preferably driven by a pressing drive, which is particularly linear, which is more particularly hydraulic, mechanical or electrical. In a currently preferred embodiment the pressing device comprises one or more cylinders, such as hydraulic cylinders. The pressing device preferably comprises a displacement encoder for realizing different stopping positions of the pressing elements, such that the material, i.e. the green brick, can have different sizes / thicknesses.

[0015] The mould can also form part of the pressing device by moving the mould toward the pressing elements during pressing with the pressing elements, while the pressing elements move toward the mould 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 moveable mould is driven by a mould drive which operates in similar manner as the pressing drive.

[0016] When pressing the material it is possible, if desired, to apply texture, logos, text, sand, dyes and / or the like to one or more sides of the green bricks. Such a structure on one or more sides of the green brick can here have a decorative / aesthetic and / or functional purpose. Such a texture can thus give the green brick the appearance of a hand-moulded brick, natural stone or other appearance of choice, giving the green brick a more vivid appearance. Such a texture can also improve adherence of a green brick to for instance a wall, for example with adhesive or mortar, which for instance provides the advantage that it can be mounted better. It is also possible to provided the mould and / or the pressing elements with movable components which protrude from the mould and / or the pressing elements before or during pressing of the material in order to create more complex recesses in the green brick in this way.

[0017] The device according to the present invention provides the advantage that green bricks are obtainable directly from a mould. The device according to the invention particularly provides the advantage that green bricks provided with geometries wherein the dimension in filling and pressing direction is greater than the thickness of the green brick are obtainable directly from a mould, wherein the desired quality is preserved. The green bricks to be manufactured with the device according to the invention hereby consist of one whole, wherein substantially all the material which is introduced into the mould forms part of the green brick. This is more energy-efficient, quicker, simpler and cheaper than obtaining the intended final product from a fired manufactured basic green brick and / or manufacturing and subsequently attaching to each other a number of partial green bricks. The device according to the invention thus contributes to making the manufacture of green bricks more sustainable by saving material and energy therein. Green bricks are also manufactured more simply and rapidly because a step in which the intended green brick is cut from a basic green brick and / or is composed from a number of partial green bricks is absent.

[0018] In an advantageous embodiment according to the invention the filling angle lies between 60° and 120°, preferably between 70° and 110°, more preferably between 80° and 100°, and the filling angle is most preferably substantially perpendicular.

[0019] The filling angle is preferably such that the pressing device and the filling device do not get in each other's way. This is achieved by placing the pressing device and the filling device at an angle such that the pressing device and the filling device can be placed on and / or close to the mould simultaneously, if desired. This provides the advantage that the mould can be filled with material by means of the filling device, after which the material can be pressed in the mould immediately by means of the pressing device. This simplifies and accelerates the process of manufacturing green bricks.

[0020] In another advantageous embodiment according to the invention the pressing device is provided with a pressing block for pressing the material into a green brick in the mould in a pressing direction.

[0021] The pressing block here preferably forms part of the one or more pressing elements and the pressing block preferably fits closely in at least one part of the mould. In a particular embodiment the pressing block here also forms the positive form of the mould. The pressing block is preferably attached to the pressing drive, particularly to the hydraulic cylinder. The shape of the green brick can be modified by modifying the shape of the pressing block.

[0022] In the device according to the invention the mould comprises one or more volume controllers which are configured to control the quantity of material introduced into the mould.

[0023] The one or more volume controllers preferably determine with their shape and / or position and / or degree of opening the quantity of material that can be introduced into the mould. Such volume controllers preferably form a kind of obstruction for the material, this limiting the quantity of material in the mould. Such volume controllers can also be configured to form the green brick and so influence the shape or the appearance thereof, for instance by adjusting the thickness and / or applying a relief. The one or more volume controllers are preferably provided on both sides of the pressing device, particularly on both sides of the optional pressing elements and more particularly on both sides of the optional pressing block. The one or more volume controllers preferably extend in the pressing direction. Additionally, the one or more volume controllers preferably extend in pressing direction beyond the side of the pressing device, particularly the optional pressing elements, more particularly the optional pressing block, which is configured to make contact with the material to be moulded. In a currently preferred embodiment the one or more volume controllers are configured to control the quantity of material introduced into the mould on the sides of and / or in the corners of the mould. This provides the advantage that the quantity of material introduced into the mould can be controlled locally. This is particularly advantageous in order to prevent an accumulation of material at the outer ends / sides and / or in the corners of the mould, which can result in excessive pressing pressure and (local) damage to the green brick. The volume controllers are preferably manufactured from a material which is configured not to adhere to the material introduced into the mould. Such a material from which the volume controllers can be manufactured is for instance plastic, such as for instance PE (polyethylene), PP (polypropylene), PVC (polyvinyl chloride) and other suitable plastics.

[0024] In a further currently preferred embodiment according to the invention one or more of the one or more volume controllers co-displace with the pressing block.

[0025] The co-displacement of one or more of the volume controllers provides the advantage that, owing to their shape and / or position, such volume controllers can displace the material introduced into the mould such that pressing of the material takes place as efficiently and advantageously as possible. It is particularly if the one or more volume controllers are provided on the sides of the pressing block that, in co-displacing with the pressing block, the volume controllers displace the material introduced into the mould, preferably away from both sides of and / or the corners of the mould. This provides the advantage that the quantity of material is reduced at the outer ends and / or in the corners of the mould and additionally that this material preferably comes to lie in the centre of the mould.

[0026] In another currently preferred embodiment according to the invention one or more of the one or more volume controllers are adjustable relative to the pressing block.

[0027] One or more of the one or more volume controllers can be adjusted relative to the pressing block, for instance the position, the shape and / or the degree of opening. The position of any volume controller can preferably be adjusted, wherein it is particularly the distance over which the volume controller extends in the pressing direction beyond the side of the pressing block configured to make contact with the material to be moulded that is adjusted. One or more of the one or more volume controllers being adjustable relative to the pressing block provides the advantage that for instance the position, shape and / or the degree of opening can be set individually per volume controller, this increasing the efficiency of the manufacturing process. It is particularly the position of a volume controller that can be adjusted on one of both the sides such that the ideal quantity of material is achieved on that one of both the sides, while this is also the case for another one of both the sides of the pressing block. The quality of the intended green brick can thus be modified in simple manner by adjusting the volume controllers.

[0028] In an advantageous embodiment according to the invention the device further comprises a bottom plate for closing off the mould.

[0029] Such a bottom plate is preferably configured to close off the mould and here keep the material in the mould while a pressing pressure is exerted thereon by the pressing device. The bottom plate is preferably provided with an openable closing element, such as a hatch, which is configured to provide access to the material, particularly to the pressed material, i.e. the green brick. It is however also possible to envisage the bottom plate being removed as a whole, for instance by sliding away or folding away, in order to provide access to the material. Such a bottom plate provides the advantage that the material remains in the mould, particularly during pressing, and that for instance a user can be given access to the (pressed) material. This embodiment is applicable irrespective of the one or more volume controllers.

[0030] In another advantageous embodiment according to the invention the device further comprises a movable closing plate for closing off the mould in the filling direction.

[0031] Such a closing plate provides similar advantages as described above for the bottom plate. The movable closing plate is preferably configured to close the side of the mould lying opposite the side of the mould closing the bottom plate. The closing plate is preferably movable in the filling direction, pressing direction and any other desired directions, such that the closing plate can be positioned on and / or close to the mould and can be placed on the mould in filling direction in order to close off the mould. This embodiment is applicable irrespective of the one or more volume controllers.

[0032] In a further advantageous embodiment according to the invention the bottom plate and the closing plate extend parallel to the pressing direction.

[0033] Such an extension of the bottom plate and the closing plate provides the advantage that the bottom plate and the closing plate close off two substantially parallel sides of the mould. The pressing device, the optional pressing elements and / or the optional pressing block here preferably moves / move between the bottom plate and the closing plate in pressing direction. The bottom plate and the closing plate in particular are here substantially in contact with the pressing device, the optional pressing elements and / or the optional pressing block, such that the bottom plate and the closing plate close off the mould. This embodiment is applicable irrespective of the one or more volume controllers.

[0034] In another advantageous embodiment according to the invention the mould is provided with one or more inserts.

[0035] Such inserts can be provided on one or more sides of the mould. Different inserts can also be provided on different sides of the mould. Such inserts are configured to modify the shape of the green brick without modifying the mould itself. This provides the advantage that different green bricks can be manufactured with the same mould by modifying one or more inserts provided on the mould. Providing one or more inserts on the mould hereby provides the advantage that the manufacturing process of, particularly different, green bricks takes place more efficiently and costs are reduced. The device according to the invention preferably further comprises a buffer with a plurality of different inserts, such that a wide range of different inserts is available for being provided on one or more sides of the mould. This embodiment is applicable irrespective of the one or more volume controllers.

[0036] In a further advantageous embodiment according to the invention the one or more inserts are provided with one or more profiles.

[0037] Such profiles comprise texture, logos, text and the like. In addition, more complex recesses, such as hollowed portions, are also possible. Different profiles can be provided on different inserts. When providing a profile on an insert provided on a mould, a negative of the provided profile will be imparted to the green brick when it is pressed. Such a profile can also be provided on the mould already, this rendering provision of such an insert on the mould unnecessary. Providing one or more profiles on one or more inserts provides similar advantages as described above, particularly as described for the pressing device. This embodiment is applicable irrespective of the one or more volume controllers.

[0038] In an advantageous embodiment according to the invention the mould comprises one or more fixing elements which are configured to fix the one or more inserts in the mould.

[0039] Such fixing elements can comprise mechanical elements and / or other suitable fixing elements, such as adhesive, to fix the one or more inserts in the mould. Such mechanical elements comprise fastening means, such as bolts, screws and other suitable fastening means, and other suitable mechanical elements. Such mechanical elements can be provided between an insert and the side of the mould on which or at which this insert is provided. It is also possible for such mechanical elements to press and / or clamp the insert onto the side of the mould on which / at which this insert is provided. In a currently preferred embodiment according to the invention the fixing elements are mechanical elements which are provided on both sides of the pressing device, particularly the optional pressing elements and more particularly the optional pressing block, and which push one or more inserts against a side of the mould. The one or more volume controllers are here preferably situated between the fixing elements and the optional pressing block of the pressing device. Such a position of the one or more fixing elements provides the advantage that the one or more inserts are fixed at their outer ends and thereby leave the shape of the mould substantially unaffected. It is however also possible to envisage such fixing elements being configured to mould the green brick and so influence the shape or the appearance thereof, for instance by adjusting the thickness and / or applying a relief. One or more fixing elements can be brought into the desired position in the mould by moving the components of the mould toward each other, i.e. closing the mould. The fixing elements can here be locked by for instance (conical) pins. This embodiment is applicable irrespective of the one or more volume controllers.

[0040] In another advantageous embodiment according to the invention the one or more profiles comprise one or more grooves configured to provide the green brick with a retention groove for securing the manufactured green brick by means of mechanical retention.

[0041] Such a groove which is provided in or on the profiles and / or the mould can comprise a thinner flanged edge and / or an upright edge. Providing such a retention groove on a green brick provides the advantage that the green brick, particularly a corner strip and / or brick slip, can be secured by means of mechanical retention, since a groove along the edge of the green brick enables this. This has the advantage that the mechanical retention prevents that or at least reduces the risk that the manufactured green brick comes away from for instance a wall and can thereby cause damage to the surrounding area and / or cause injury to bystanders. Such a retention groove can be provided on a green brick in particularly efficient manner in a device in an embodiment according to the invention in that the filling direction and the pressing direction lie at a filling angle. This filling angle makes it possible to arrange such a retention groove better than in a prior art device, whereby such a retention groove maintains its shape better. This is particularly possible in combination with providing one or more profiles on the mould and / or with providing one or more inserts provided with one or more profiles on the mould. In a device according to the invention the assembly of an insert with such a groove has here been found particularly effective for arranging a retention groove on a green brick, particularly in the case of a corner strip. This embodiment is applicable irrespective of the one or more volume controllers.

[0042] In yet another advantageous embodiment according to the invention the device according to the invention further comprises a demoulding device for removing the manufactured green brick from the mould.

[0043] The demoulding device is configured to release the manufactured green brick from the mould (in forced manner) if it does not detach from the mould when the mould parts move apart and releases through for instance the force of gravity. Such a demoulding device can for instance comprise a gripper which engages on the green brick. It is however also possible to envisage the green brick being vibrated or shaken loose in order to overcome the attractive force between the green brick and the walls of the mould. The optional bottom plate can also comprise a demoulding device, for instance by folding away / sliding away (a part of) the bottom plate, whereby the green brick is pulled along. The green brick can further be released by providing an underpressure and / or overpressure on one or more sides of the mould. In a currently preferred embodiment according to the invention the mould is provided with push-out pins and / or differently formed parts which are preferably provided in one or more of the mould parts and protrude from one or more of the mould parts in use in order to push the green brick off the mould parts. The green brick is preferably removed from the mould together with one or more of the optional one or more inserts. It is however also possible for one or more of the optional one or more inserts to remain in the mould during removal of the green brick from the mould. Such a demoulding device provides the advantage that the green brick is releasable / removable from the mould and the final product can thus be released from the mould, for instance in order to perform further processes elsewhere. The preferred embodiment wherein one or more inserts are released together with the green brick additionally provides the advantage that the green brick can be removed from the insert outside of the mould, where it is readily accessible and processes, such as covering with sand, can for instance be performed thereon (once again). This embodiment is applicable irrespective of the one or more volume controllers.

[0044] In a further advantageous embodiment according to the invention the device according to the invention further comprises a discharge conveyor for transporting the manufactured green brick.

[0045] Such a discharge conveyor is preferably provided under the mould in use, whereby the green brick can come to lie on the discharge conveyor through the force of gravity. In use the discharge conveyor is more preferably positioned close to and under the mould such that the green brick can come to lie on the discharge conveyor substantially undamaged through the force of gravity. In a currently preferred embodiment according to the invention the discharge conveyor is movable, particularly vertically, such that the discharge conveyor can move from and to the mould in order to receive the green brick or to create space around the mould. In an alternative embodiment it is also possible for the mould to move toward the discharge conveyor and away from the discharge conveyor and / or for the mould and the discharge conveyor to move away from each other and toward each other. This provides the advantage that in use the discharge conveyor can be positioned close to the mould in order to receive the green brick and can be positioned further away from the mould in order to remain out of the way of for instance other components of the device according to the invention, this allowing the manufacturing process to progress more efficiently. The discharge conveyor further provides the advantage that the manufactured green brick can be transported to a location where this green brick can undergo a follow-on process and / or can be picked up by a user. This embodiment is applicable irrespective of the one or more volume controllers.

[0046] In another advantageous embodiment according to the invention the device according to the invention further comprises a mould conveyor for moving the mould along the filling device and / or the pressing device.

[0047] Such a mould conveyor makes it possible to transport the mould, for instance along different components of the device according to the invention, such as the filling device and the pressing device. In this way a plurality of the same or different moulds can move along the filling device and / or pressing device on a mould conveyor, whereby a plurality of green bricks can be manufactured in rapid succession. The direction in which the mould conveyor moves preferably lies at right angles to the filling device and at right angles to the pressing device, whereby the plurality of moulds move along the filling device and the pressing device. This embodiment is applicable irrespective of the one or more volume controllers.

[0048] In an advantageous embodiment according to the invention the pressing direction is adjustable.

[0049] In this advantageous embodiment the direction in which the press presses the material in the mould can be adjusted. Changing the pressing direction for a determined mould changes the sliding of the material along the walls of the mould during pressing and prevents potential problems in the production process. The pressing direction affects, among other things, different aspects of the production process and the final product, such as the internal structure and strength of the material, the mechanical properties, the aesthetics and the texture. The pressing direction is preferably perpendicular to the side of the moulds being pressed. In determined geometries, such as in the case of corner strips, this is however not possible because the green brick comprises a plurality of sides which lie at angles relative to each other. Particularly, two sides of a corner strip usually lie at an angle of 90°. In such a case the pressing direction is preferably set such that the angle between the pressing direction and the sides of the mould for the corner strip amounts to substantially 45°. This embodiment has the advantage that the material properties of the manufactured green brick can be modified without any adjustment of the mould being necessary, which results in a cost reduction. Such an adjustable pressing direction can be applied flexibly for green bricks of different shapes and sizes, including for instance retention grooves and other profiles. This embodiment is applicable irrespective of the one or more volume controllers.

[0050] In another advantageous embodiment according to the invention the device according to the invention is configured to manufacture one or more corner strips.

[0051] In this advantageous embodiment corner strips can be obtain directly from a mould. This has the advantage that it is more energy-efficient and less expensive than forming, particularly cutting, one or more corner strips from an already fired, manufactured (basic) green brick. This embodiment is applicable irrespective of the one or more volume controllers.

[0052] The invention further also relates to a method according to claim 13.

[0053] The method provides similar advantages and effects as described for the device.

[0054] In an advantageous embodiment according to the invention the method further comprises of controlling the quantity of material introduced into the mould by means of one or more volume controllers. Such an embodiment according to the invention provides similar advantages and effects as described for the device. This embodiment is applicable irrespective of the one or more volume controllers.

[0055] In another advantageous embodiment according to the invention the method further comprises of closing off the mould by means of a bottom plate and / or a closing plate. Such an embodiment according to the invention provides similar advantages and effects as described for the device. This embodiment is applicable irrespective of the one or more volume controllers.

[0056] In another advantageous embodiment according to the invention the method further comprises of providing one or more inserts on the mould. Such an embodiment according to the invention provides similar advantages and effects as described for the device. This embodiment is applicable irrespective of the one or more volume controllers.

[0057] In a further advantageous embodiment according to the invention the method further comprises of removing the manufactured green brick from the mould by means of a demoulding device. Such an embodiment according to the invention provides similar advantages and effects as described for the device. This embodiment is applicable irrespective of the one or more volume controllers.

[0058] In an advantageous embodiment according to the invention the method further comprises of displacing the manufactured green brick removed from the mould by means of the discharge conveyor. Such an embodiment according to the invention provides similar advantages and effects as described for the device. This embodiment is applicable irrespective of the one or more volume controllers.

[0059] In another advantageous embodiment according to the invention the method further comprises of moving the mould along the filling device and / or pressing device by means of a mould conveyor. Such an embodiment according to the invention provides similar advantages and effects as described for the device. This embodiment is applicable irrespective of the one or more volume controllers.

[0060] In another advantageous embodiment according to the invention the method further comprises of providing one or more corner strips as green brick. Such an embodiment according to the invention provides similar advantages and effects as described for the device. This embodiment is applicable irrespective of the one or more volume controllers.

[0061] In a preferred embodiment according to the invention the method further comprises of providing a relatively dry clay with a moisture percentage of less than 20% mass as clay material. In a further advantageous embodiment according to the invention the (relatively) dry clay is provided with a moisture percentage of less than 18% by mass, preferably less than 15% by mass, more preferably less than 12% by mass, still more preferably less than 10% by mass, still more preferably less than 9% by mass and most preferably less than 8% by mass. This embodiment is applicable irrespective of the one or more volume controllers.

[0062] In these advantageous embodiments according to the invention a dry clay with a relatively low percentage by mass of moisture is used. This is also referred to as granulated moist clay, as well as soft clay. This has an energy advantage because it requires less energy to fire a manufactured green brick with a lower percentage by mass of moisture. This energy advantage further entails a cost reduction, since the costs of the energy consumption are lower. This embodiment is applicable irrespective of the one or more volume controllers.

[0063] 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: Figure 1A is a perspective view of a pressing device in a device according to the invention; Figure 1B is a perspective view of a corner strip as green brick in a device according to the invention; Figure 2 is a perspective view of a device according to the invention; Figure 3 is a perspective view of a device according to the invention provided with a moveable closing plate and a discharge conveyor; Figure 4 is a perspective view of an alternative embodiment of a device according to the invention provided with a mould conveyor and a discharge conveyor; Figure 5 is a block diagram representation of a method according to the invention; and Figure 6 is a front view of the device shown in Figure 4 incorporated in a production line.

[0064] Device 2 (figure 1A) is configured to manufacture green bricks 4 from material 6, such as clay material. Green brick 4 (figure 1B) has length L, width W, height H and thickness X. In apparatus 2 according to the invention height H is preferably the dimension in filling direction F.

[0065] In the shown embodiment according to the invention device 2 is provided with mould 8 for moulding material 6 and pressing device 10 for pressing material 6 in mould 8 in pressing direction P. In a particular embodiment according to the invention pressing direction P is adjustable. Pressing device 10 comprises pressing block 12 and (hydraulic) pressing cylinder 14, which are mutually connected by means of pressing plate 16. Pressing block 12 and mould 8 fit tightly into each other in the shown embodiment. In the shown embodiment according to the invention mould 8 is closed by bottom plate 18 and is additionally provided with insert 20 which is fixed in mould 8 by fixing element 22. In the shown embodiment fixing elements 22 are provided on both sides of pressing block 12 of pressing device 10. In the shown embodiment fixing elements 22 are locked in mould 8 by conical pins 23 (figure 2). Further provided between fixing elements 22 and pressing block 12 are volume controllers 24. Volume controllers 24 are also connected to pressing device 10 by means of pressing plate 16, whereby volume controllers 24 co-displace with pressing block 12 in the shown embodiment according to the invention.

[0066] In the shown embodiment according to the invention filling device 26 (figure 2) comprises hopper 28 for introducing material 6 into mould 8 in filling direction F. Filling direction F here lies at filling angle α relative to pressing direction P. Hopper 28 comprises a hopper opening 30 and hopper outlet 32, the shape of which is substantially equal to the shape of mould 8, this resulting in a uniform filling of material 6 in mould 8. Hopper 28 is provided here on filling plate 34, which in the shown embodiment is slidable over mould 8 by means of (hydraulic) filling cylinder 36. In the shown embodiment according to the invention mould 8 is also connected to (hydraulic) mould cylinder 38 which is driven by mould drive 40. Mould cylinder 38 enables material 6 to be pressed in mould 8 from two sides by moving mould 8 in a direction opposite to pressing direction P while pressing block 12 moves in pressing direction P.

[0067] In the shown embodiment closing plate 42 (figure 3), which is movable in filling direction F by means of closing cylinder 44 and closing drive 46, is situated above mould 8 in use. In the shown embodiment closing plate 42 is a circular plate. It is however also possible to envisage closing plate 42 having a different form, as long as closing plate 42 closes off the part of mould 8 in which material 6 is pressed.

[0068] Owing to an openable hatch (not shown) in bottom plate 18, material 6, i.e. green brick 4, can be removed from mould 8 by a demoulding device (not shown). Such a demoulding device comprises for instance knock-out pins in mould 8 and / or pressing block 12, which can push pressed material 6, i.e. green brick 4, off a side of mould 8 or off pressing block 12. In the shown embodiment material 6 can find its way from mould 8 and then onto discharge conveyor 48 in demoulding direction R. This is for instance possible with the force of gravity, or using a gripper (not shown). Discharge conveyor 48 comprises conveyor belt 52 which is arranged on rollers 50 and which transports green bricks 4 away from device 2 in discharge direction D, where green brick 4 can for instance undergo a follow-on process and / or can be picked up by a user. Discharge conveyor 48, particularly rollers 50, is / are driven by discharge drive 54. Discharge conveyor 48 is preferably moveable, particularly in and opposite to demoulding direction R, such that discharge conveyor 48 can move toward mould 8 and away from mould 8. This is made possible by (schematically shown) discharge cylinders 56.

[0069] In an alternative embodiment of device 2 according to the invention (figure 4) the device 2 is provided with: mould 8 for moulding material 6; filling device 9 for introducing material 6 into mould 8 in filling direction F; pressing device 10 for pressing material 6 in mould 8 in pressing direction P; and mould conveyor 112 for moving mould 8 along filling device 9 and pressing device 10.

[0070] The prepared material 6 is supplied to filling device 9, this consisting of hopper 132 and filling plate 134 which is provided with filling hole 136. In the shown embodiment filling hole 136 has the shape of green brick 4, this being a corner strip in the shown embodiment. It is however also possible to envisage filling hole 136 having a different shape than green brick 4.

[0071] Mould 8 moves along filling direction 9 on mould conveyor 112 in transport direction T. In the shown embodiment mould 8 comprises positive form 114, negative form 116 and lower closing element 118. Upper closing element 120 is designated as optional addition to mould 8. It is however also possible to envisage mould conveyor 112 functioning as one or more components of mould 8. Mould 8 further comprises a cavity, mould cavity 138, between the different components of mould 8.

[0072] In an advantageous embodiment of the present invention mould 8 is provided with one or more inserts 124. Such inserts 124 can be added to mould 8 when it is moving on mould conveyor 112, before mould 8 has passed filling device 9. With such inserts 124 it is possible for them to be provided with one or more profiles 122, for instance to improve the aesthetics of green brick 4. It is however also possible for such profiles 122 to be provided directly on mould 8. In an advantageous embodiment of the present invention one or more profiles 122 comprise one or more grooves 126, such as retention grooves.

[0073] When mould 8 passes filling device 9 on mould conveyor 112, material 6 is introduced through filling cavity 136 of filling plate 134 into mould 8 in filling direction F by filling device 9. Material 6 is particularly introduced into mould cavity 138 by filling device 9.

[0074] Mould 8 continues to move toward pressing device 10 in transport direction T on mould conveyor 112. In Figure 4 pressing device 10 is provided with press 140, comprising inner cylindrical rod 142 which is arranged guidably in outer cylindrical rod 144. Pressing device 10 further comprises pressing drive 146, which is provided with pressing controller 148. By means of pressing drive 146 pressing controller 148 controls the position of inner cylindrical rod 142 in outer cylindrical rod 144 and the speed and acceleration at which two cylindrical rods 142, 144 move relative to each other. It is however also possible to envisage pressing device 10 taking a different form than shown in Figure 4.

[0075] Pressing device 10 is configured to press material 6 in mould 8 in pressing direction P. In the shown embodiment inner cylindrical rod 142 of press 140 moves toward positive form 114 of mould 8 in order to move positive form 114 of mould 8 toward negative form 116 of mould 8. It is however also possible for press 140 to engage on negative form 116 of mould 8 and for negative form 116 of mould 8 to move toward positive form 114 of mould 8, or a combination thereof.

[0076] Pressing device 10 comprises a press 140 which presses material 6 in mould 8 in pressing direction P. Pressing direction P is adjustable here, whereby material 6 can be pressed in mould 8 in different pressing directions P. Said filling direction F and pressing direction P also lie at filling angle α in this shown embodiment. In the shown embodiment pressing direction P is perpendicular to filling direction F, this having the advantage that mould 8 is filled vertically in filling device 9 and is pressed horizontally in pressing device 10. This makes it possible to manufacture for instance a corner strip from material 6 in an advantageous embodiment of the present invention.

[0077] When mould 8 has passed pressing device 10 in transport direction T by means of mould conveyor 112, green brick 4 has been pressed. In an advantageous embodiment of the present invention manufactured green brick 4 is then removed from mould 8 in demoulding direction R in (schematically shown) demoulding device 128. Demoulding device 128 comprises demoulder 150, demoulding drive 152 and demoulding controller 154. Demoulder 150 is here driven by demoulding drive 152, which is controlled by demoulding controller 154. It is however also possible to envisage demoulding device 128 comprising fewer, more or other elements. In an advantageous embodiment demoulder 150 comprises an ejector (not shown) in the form of manufactured green brick 4. Such an ejector can remove manufactured green brick 4 from mould 8 when the ejector makes contact with green brick 4 and the ejector pushes green brick 4 out of mould 8 in releasing direction R. In that case green brick 4 slides along positive form 114 and negative form 116 of mould 8 in demoulding direction R until green brick 4 no longer makes contact with mould 8. In an advantageous embodiment demoulder 150 can for instance comprise an extractor (not shown), configured to extract manufactured green brick 4 from mould 8.

[0078] In an advantageous embodiment of the present invention the released manufactured green brick 4 comes to lie on discharge conveyor 130 for the purpose of discharging manufactured green brick 4. Discharge conveyor 130 moves in discharge direction D to a location where green brick 4 can undergo a follow-on process and / or can be picked up by a user. Discharge conveyor 130 is driven by discharge drive 156, which is controlled by discharge controller 158.

[0079] Mould conveyor 112 comprises return conveyor 160 whereby, after manufactured green brick 4 has been removed from mould 8, mould 8 returns to the position upstream of filling device 9 where mould 8 can be reused. This return conveyor 160 is driven by mould drive 162, which preferably also drives mould conveyor 112. Mould drive 160 is controlled by mould controller 164, which controls the position, speed and acceleration of return conveyor 160 and mould conveyor 112. It is however also possible to envisage mould controller 164 controlling return conveyor 160 and mould conveyor 112 individually, and / or there being two separate drives (not shown) for return conveyor 160 and mould conveyor 112.

[0080] In a particular embodiment according to the invention, particularly in combination with the alternative embodiment of device 2 according to the invention (figure 4), method 202 (figure 5) for manufacturing green bricks from material 6 comprises the steps of: providing starting material 204, comprising device 2 for manufacturing green bricks 4 from material 6, preferably dry clay; providing a design 206 for green brick 4, such as determined geometries, for instance that of a corner strip, thicknesses, lengths and profiles, for instance a (retention) groove; setting 208 filling angle α and / or pressing direction P, wherein filling angle α is preferably perpendicular and pressing direction P depends inter alia on intended green brick 4; introducing 210 material 6 into filling device 9, comprising of introducing material 6 into hopper 132 and then introducing it into filling hole 136; introducing 212 material 6 into mould 8, comprising of positioning 210 mould 8 relative to filling device 9 and then introducing material into mould hole 138; transporting 214 mould 8 between filling device 9 and pressing device 10 by means of mould conveyor 112; pressing 216 material 6 in mould 8 by means of pressing device 10; transporting 218 mould 8 further between pressing device 10 and demoulding device 128 by means of mould conveyor 112; demoulding 220 manufactured green brick 4 by means of demoulding device 128; finishing 222 manufactured green brick 4 after this green brick 4 has been removed from mould 8; and providing manufactured green brick 4 removed from mould 8 as final product 224.

[0081] The alternative embodiment of device 2 according to the invention (figure 4) can be incorporated in production line 302 (figure 6) as an advantageous embodiment according to the invention. Considering the shown embodiment is a front view, pressing device 10 is not shown therein because pressing device 10 is in this case situated behind mould 8 and is thereby not visible. Optional demoulding device 128 and optional discharge conveyor 130 have also been omitted here, since these are particular embodiments of the present invention.

[0082] A number of mould 8 pass filling device 9 by means of mould conveyor 112, wherein filling device 9 comprises hopper 132 and filling plate 134 provided with filling hole 136 (not shown). Filling device 9 further comprises frame 304 on which hopper 132 and filling plate 134 are mounted and receptacle 306 for catching excess material 6 which finds its way outside mould 8 during filling.

[0083] Moulds 8 in production line 302 are mutually connected in an endless series by means of pivoting connections 308. Moulds 8 can tilt relative to each other by means of these pivoting connections 308. In this way, when manufactured green brick 4 has been released from mould 8 after passing demoulding device 128, mould 8 can return via return conveyor 160 to the position upstream of filling device 9 where mould 8 can be reused.

[0084] In the shown advantageous embodiment of the present invention mould drive 162 comprises transport conveyor 310 and drive arm 312. Drive arm 312 is arranged engageably on mould conveyor 112 and / or return conveyor 160 on one side and arranged guidably on transport conveyor 310 on the other. When drive arm 312 engages on mould conveyor 112 and / or return conveyor 160, this drive arm 312 can be guided over transport conveyor 310 by means of a drive mechanism (not shown), whereby moulds 8 co-displace with mould conveyor 112 and / or return conveyor 160.

[0085] In addition to mould drive 162, production line 302 also comprises a pair of mould stops 314 which are likewise arranged engageably on mould conveyor 112 and / or return conveyor 160. When mould stop 314 engages on mould conveyor 112 and / or return conveyor 160, mould stop 314 forces standstill of mould conveyor 112 and / or return conveyor 160. By means of this system mould conveyor 112 can be moved while return conveyor 160 is stationary, or vice versa, in an advantageous embodiment of the present invention.

[0086] 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 mould for moulding the material; - a filling device for introducing the material into the mould in a filling direction; and - a pressing device for pressing the material into a green brick in the mould in a pressing direction; wherein the pressing direction and the filling direction lie at a filling angle and wherein the mould comprises one or more volume controllers which are configured to control the quantity of material introduced into the mould.

2. Device according to claim 1, wherein the filling angle lies between 60 and 120 degrees, preferably between 70 and 110 degrees, more preferably between 80 and 100 degrees, and is most preferably substantially perpendicular.

3. Device according to any one of the foregoing claims, wherein the pressing device is provided with a pressing block for pressing the material into a green brick in the mould in a pressing direction, wherein one or more of the one or more volume controllers preferably co-displace with the pressing block and / or are adjustable relative to the pressing block.

4. Device according to any one of the foregoing claims, further comprising a bottom plate for closing off the mould and / or a moveable closing plate for closing off the mould in the filling direction, wherein the bottom plate and the closing plate preferably extend parallel to the pressing direction.

5. Device according to any one of the foregoing claims, wherein the mould is provided with one or more inserts, wherein the one or more inserts are preferably provided with one or more profiles, wherein the one or more profiles preferably comprise one or more grooves which are configured to provide the green brick with a retention groove for securing the manufactured green brick by means of mechanical retention.

6. Device according to the foregoing claim, wherein the mould comprises one or more fixing elements which are configured to fix the one or more inserts in the mould.

7. Device according to any one of the foregoing claims, further comprising a demoulding device for removing the manufactured green brick from the mould.

8. Device according to any one of the foregoing claims, further comprising a discharge conveyor for transporting the manufactured green brick.

9. Device according to any one of the foregoing claims, further comprising a mould conveyor for moving the mould along the filling device and / or the pressing device.

10. Device according to any one of the foregoing claims, wherein the pressing direction is adjustable.

11. Device according to any one of the foregoing claims, wherein the device is configured to manufacture one or more corner strips.

12. Method for manufacturing green bricks from a material, such as clay material, comprising the steps of: - providing a device according to any one of the foregoing claims; - introducing the material into the mould in the filling direction by means of the filling device; - controlling the quantity of material introduced into the mould by means of one or more volume controllers; and - pressing the material into a green brick in the mould in the pressing direction by means of the pressing device.

13. Method according to the foregoing claim, further comprising of closing off the mould by means of a bottom plate and / or a closing plate and / or providing one or more inserts on the mould and / or removing the manufactured green brick from the mould by means of a demoulding device and / or displacing the manufactured green brick removed from the mould by means of the discharge conveyor.

14. Method according to claim 13 or 14, further comprising of moving the mould along the filling device and / or pressing device by means of a mould conveyor and / or providing clay with a moisture percentage of less than 20% by mass as clay material, wherein the clay is preferably provided with a moisture percentage of less than 18% by mass, preferably less than 15% by mass, more preferably less than 12% by mass, still more preferably less than 10% by mass, still more preferably less than 9% by mass and most preferably less than 8% by mass.

15. Method according to any one of the claims 12-14, further comprising of providing one or more corner strips as green brick.

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