Method and apparatus for manufacture of unitary lightweight concrete composite blocks

Abstract

A method and apparatus for manufacturing unitary concrete blocks includes a form that defines the desired shape of the unitary concrete block. A form loading station delivers a lightweight concrete composite into the form. A station conveyor conveys the form from the form loading station through a curing oven. In the curing oven, the composite-filled form is cured into a unitary concrete block. The station conveyor conveys the form to a block removal station that removes the unitary concrete block from the form. The station conveyor returns the form to the form loading station to manufacture more unitary concrete blocks. For increased production, multiple forms can be conveyed between stations simultaneously. Additionally, a metering ingredient assembly may be used to deliver appropriate amounts of desired ingredients to a mixer for producing the lightweight concrete composite.

1 - 69 . (canceled).  
   
   
       70 . A method for manufacturing unitary concrete blocks, comprising: 
 mixing desired ingredients into a composite;    loading the composite into a form of a desired shape;    curing the composite into a unitary concrete block; and    removing the unitary concrete block from the form.    
   
   
       71 . The method according to  claim 70 , further comprising grinding polystyrene into small particles.  
   
   
       72 . The method according to  claim 70 , further comprising metering predetermined amounts of desired ingredients.  
   
   
       73 . The method according to  claim 72 , wherein metering predetermined amounts of desired ingredients comprises: 
 conveying the desired ingredient into a hopper;    measuring an amount of the desired ingredient; and    delivering the desired ingredient to a mixer.    
   
   
       74 . The method according to  claim 70 , wherein loading the composite into a form of desired shape comprises: 
 removing a cap from the form;    delivering the composite into the form;    replacing the cap onto the form; and    compressing the form, whereby the composite is sealed therein.    
   
   
       75 . The method according to  claim 73 , wherein delivering the composite into the form comprises: 
 conveying a screed box to a loading position, whereby the screed box is located directly over the form;    delivering the composite to a leveling hopper contained within the screed box; and    sliding the leveling hopper back and forth within the screed box, whereby the composite fills the form with composite.    
   
   
       76 . The method according to  claim 74 , further comprising rotating an auger to evenly distribute the composite throughout the leveling hopper.  
   
   
       77 . The method according to  claim 74 , further comprising conveying the screed box to a retracted position.  
   
   
       78 . The method according to  claim 70 , wherein the removing the unitary concrete block from the form comprises: 
 locking a bottom tube assembly of the form;    uncoupling a wall assembly and a cap from the bottom tube assembly of the form;    lifting the wall assembly and the cap from a lower level to an intermediate level, whereby the wall assembly and the cap separate form the bottom tube assembly; and    unloading the unitary concrete block.    
   
   
       79 . The method according to  claim 78 , wherein unloading the unitary concrete block comprises: 
 rotating a swing-arm assembly to a loading position;    disassembling the wall assembly, whereby the unitary concrete block separates from the wall assembly and the cap;    loading the unitary concrete block onto the swing-arm assembly;    lifting the wall assembly and the cap from the intermediate level to an upper level;    rotating the swing-arm assembly to an unloading position; and    unloading the unitary the concrete block.    
   
   
       80 . The method according to  claim 79 , further comprising assembling the form.  
   
   
       81 . The method according to  claim 80 , wherein the step of assembling the form comprises: 
 assembling the wall assembly; and    lowering the wall assembly and cap assembly to the lower level, whereby the wall assembly and cap seats on the bottom tube assembly.