JPS6016342B2 - Building block manufacturing method and device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to building blocks of the type in which at least one cavity is formed, the cavity extending through or near the block from one side to the opposite side.

A block with at least one such cavity will be referred to herein simply as a "building block." More particularly, the present invention relates to a method and apparatus for filling at least one cavity of a building block with cured foam of aminoplast resin to enhance the insulation properties of the building block.

According to the invention, a cavity in a building block filled with a cured foam of aminoplast resin is obtained by a method comprising the following steps: a cured foam from a solution of aminoplast resin and a hardening agent for the resin. and placing the cavity at and in sealing relationship with one end of the foam discharge tube, and introducing the curable foam through the discharge tube and into the cavity until back pressure is created within the discharge tube. It is to inject.

Preferably, successive cavities are filled in turn in the manner just described, the tube traversing the cavities (or the cavities starting transversely to the tube) at such a speed that each cavity is filled.

To date, a number of foam discharge pipes have been used which are connected via a distributor to a common foam machine, the free ends of which are simply inserted loosely into the same number of cavities or directly above them. placed.

Although it takes time to eject the foam to fill all the cavities, this method provides an unsatisfactory degree of pressure and density co-control of the fill, due to the difficulty of balancing the flow rates in the individual tubes. By filling the individual cavities in the tube until a backpressure is created, the density of the filling can be kept strictly constant. Additionally, if the block is porous, the back pressure can be used to force some of the foam into the body of the block, thus "trapping" the foam within the cavity. It is advantageous for the method of the invention to be linked to the block manufacturing process, for example immediately after the curing of the "green" block: in this case, of course, a pre-chilled water mist treatment is carried out to cool the thermoset block and shrinkage of the foam occurs during curing. It can help to limit the

For convenience, the blocks are arranged in rows on a template or conveyor strip while the foam discharge tube traverses successive rows of blocks, these successive rows being fed into said tube by means of an indexing device. A simple stop-and-go operation of the foaming device is sufficient if the jetting does not cease for longer than the gel time of the particular foam specification being used. If long delays are still likely, a device must be provided to remove material from the foam machine and the discharge pipe running therebetween in order to avoid gelling within the pipe. According to a further aspect of the invention, the apparatus for carrying out the method of the invention includes a foam discharge tube having a foam outlet and the outlet being directed into the cavity while creating a seal around the green at the mouth of the cavity. including devices capable of acting to do so. Preferably, the end of the foam discharge tube is in a "shoe profile" which contains the outlet and is fitted to traverse the rows of blocks so as to lead the outlet one after another into the cavity to be filled.

In a particularly preferred embodiment of the invention, a template is placed between the shoe profile and the block, and a hole corresponding to the cavity to be sealed is provided in the template across the top of the shoe profile. provided. Advantageously, the surface of the template in contact with the block has a resilient surface, which can provide a seal around each hole to prevent or at least limit leakage of foam across the face of the block.
The last village is preferably designed such that its foam outlet can coincide with one or more holes in the template at the same time, and conveniently the foam outlet is such that the last village stops the foaming device. It is arranged so that it can traverse continuously relative to the row of blocks without any problems.

Preferably, the shoe profile is pressed resiliently against the template so as to exert pressure on it, thus controlling the maximum back pressure that occurs in the discharge tube.

By using templates in this way it is possible to limit the risk that the block will be covered with foam on its outer surface. Furthermore, the resilient attachment of the shoe profile provides the properties of a safety valve, whereby if the pressure in the tube ever exceeds the pressure of the shoe profile against the template, the foam will It can escape from the surface of the board. Preferred embodiments of the invention will now be described by way of example with reference to the accompanying drawings.

In the attached figure, two rows of building blocks 3 are standing side by side on a platform 4.

Above the block is placed a template 5 with a plurality of holes 6 corresponding to its cavities. On the underside of the template is a layer of elastic foam 8.
In use, this forms a sealing material between the template that presses against the block and the top surface of the block. On the upper surface of the opposite template, a shoe profile 9 is attached in the direction of the arrow so as to extend back and forth over the template, that is, across the length of the two rows of blocks. The shoe profile is connected by a flexible tube 10 to a conventional urea formaldehyde resin foaming device; this device is not shown and need not be described in detail for present purposes.
The shoe profile has a spring device (not shown for clarity).
It is elastically pressed against the mold plate by the mold plate and has a foam discharge row 1 on the contact surface 12 with the mold plate.

As shown in FIGS. 1 and 2, the outlet 11 corresponds to the hole 6 in the template, but the shape does not (and need not necessarily) correspond thereto. The size of the outlet 11 is such that when it is transferred onto the template it completely seals one cavity before it overlaps the next cavity and begins its sealing. In fact, as shown, the outlet fills two cavities simultaneously, but in different aligned blocks.
In operation, the shoe profile starts at one end of the row of blocks and the foaming device is activated to fill the first pair of cavities with foam.

During filling, the shoe profile is moved through the template, and this is done at such a speed that each pair of cavities is filled to the point where a strictly constant backpressure occurs, which backpressure is applied to the wall of each block. It is sufficient to press some foam into the blocks, and these blocks are highly porous for typical cement-light aggregate blocks. At the end of a row the movement of the shoe profile is stopped and a new shoe profile is removed, for example by moving the template and, if necessary, at the same time raising it very slightly to obtain the required clearance. The row of blocks is advanced into position. The foaming may also be paused due to the time required for the start of a new row of blocks. Otherwise the foam will flow and be wasted. Although the apparatus just described relies on a selected precise travel speed, it uses a pressure sensing device, such as a switch, that responds to the back pressure created in the tube to control the travel speed or to control the foam machine. It is also possible to do so.

It will be appreciated that the embodiment just described can be adapted to separate blocks simply by applying another template with the appropriate hole profile.

Although it may also be necessary to adjust the traverse speed,
Otherwise, this same device should be satisfactory for a certain range of block and cavity contours.

[Brief explanation of drawings]

FIG. 1 is a partial cross-sectional plan view of an apparatus for filling the cavity of a building block with cured amino resin foam, and FIG. 2 is a side cross-sectional view of a portion of FIG. 1 taken along line A--A. Reference numeral 3 in the attached drawings represents the "architectural block" described in the claims, numeral 7 represents "cavity", and numeral 10
11 indicates a "discharge pipe", 11 indicates a "discharge port", 5 indicates a "template", and 6 indicates a "hole". many times

Claims (1)

[Scope of Claims] 1. A method for manufacturing a building block in which a cavity thereof is filled with a hardened aminoplast resin foam, which is cured from a solution of an aminoplast resin solution and a curing agent for the resin. forming a plastic foam, placing the cavity at and in sealing relationship with one end of a discharge tube of the foam, and injecting the foam into the cavity until back pressure is created in the discharge tube. A method of manufacturing architectural blocks consisting of processes. 2. The method according to claim 1, wherein successive cavities are sequentially filled by moving the end of the discharge tube across and in sealing relation with the cavity. How to make building blocks. 3. A method according to claim 1, in which successive cavities are sequentially filled by moving them into sealing relationship with the end of the discharge tube. 4. A method for manufacturing a building block according to claim 2 or 3, in which the movement is carried out by means of an indicator and foam formation is stopped during the indicator. 5. A method for manufacturing a building block according to claim 2 or 3, wherein the movement and foam formation are continuous. 6. A foaming machine having a foam discharge pipe terminating in a foam outlet, and a device for locating said outlet in a cavity of a building block such that said cavity is sealed around the edges during said placement. Building block manufacturing equipment including. 7. The device of claim 6, wherein the foam outlet is moved across and in contact with a row of building blocks so as to be successively located in successive cavities. Architectural block manufacturing equipment. 8. The apparatus of claim 7, including a template placed between the foam outlet and the block;
Apparatus for manufacturing building blocks, wherein said template has a hole defined therein to correspond to a cavity to be filled. 9. Apparatus according to claim 8, wherein the contact surface of the template with the block has a resilient surface to seal around the edges of each hole. 10. Apparatus according to claim 8 or 9, wherein the foam outlet is arranged such that it can align with one or more holes in the template at any time. 11. The device according to any one of claims 8, 9 and 10, wherein the foam outlet
A building block manufacturing device in which a building block is pressed against said template so that a pressure is exerted on said template, thereby controlling the maximum back pressure generated. 12. The device according to any one of claims 6 to 11, wherein a pressure sensing device is provided in the foam discharge pipe and detects the foaming machine and or A building block manufacturing device arranged to control the speed of movement of said foam outlet.