System, method and apparatus for fabricating environmental masonry units

摘要

Masonry units, such a blocks, are fabricated in a sequential process, using improved mold structures, such as within a production corridor of a corresponding fabrication system. A compressible masonry feedstock or formulated material, which can be de-agglomerated before use, is filled within a block mold having releasable elements. The feedstock or formulated material is then compressed within the mold structure. The compressed workpiece can be further processed, such as for any of final height adjustment, the establishment of a surface feature, or to remove cores. The block mold, having releasable elements or sides, such as using hinges or springs, is released from the formed block, wherein the formed masonry unit can be removed for curing, and wherein the block mold can be reused to fabricate a subsequent masonry unit.

主权项

1. A process, comprising:
de-agglomerating a masonry feedstock having a moisture content associated therewith with a vertical shaft mixer having an upper end and a lower end opposite the upper end, wherein the masonry feedstock is loaded into the vertical shaft mixer, wherein the vertical shaft mixer de-agglomerates the masonry feedstock to produce a compressible de-agglomerated masonry feedstock, and wherein the compressible de-agglomerated masonry feedstock exits the vertical shaft mixer through the lower end; transferring the compressible de-agglomerated masonry feedstock from the vertical shaft mixer to a supply hopper; filling an interior region of a masonry block mold with the compressible de-agglomerated masonry feedstock from the supply hopper, wherein at least a portion of the masonry block mold is releasable; consolidating the compressible de-agglomerated masonry feedstock within the masonry block mold; dynamically compressing the consolidated compressible de-agglomerated masonry feedstock to form a masonry block having a face; laterally releasing the masonry block mold from the face of the masonry block; removing the masonry block from the released masonry block mold; moving the masonry block to a curing area; and curing the masonry block; wherein the process is performed at a plurality of sequential stations; and wherein a production corridor is defined between the plurality of sequential stations.