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US2964820A - Casting jig - Google Patents

Casting jig Download PDF

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Publication number
US2964820A
US2964820A US671107A US67110757A US2964820A US 2964820 A US2964820 A US 2964820A US 671107 A US671107 A US 671107A US 67110757 A US67110757 A US 67110757A US 2964820 A US2964820 A US 2964820A
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United States
Prior art keywords
slabs
jig
spacing members
bags
lugs
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US671107A
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Irwin D Olson
Robert B Taylor
Jr Clarence B Monk
John P Wogulis
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STRUCTURAL CLAY PRODUCTS RES F
STRUCTURAL CLAY PRODUCTS RESEARCH FOUNDATION
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STRUCTURAL CLAY PRODUCTS RES F
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Priority to US671107A priority Critical patent/US2964820A/en
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Publication of US2964820A publication Critical patent/US2964820A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/041Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers for moulded articles undergoing a thermal treatment at high temperatures, such as burning, after coating
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S425/00Plastic article or earthenware shaping or treating: apparatus
    • Y10S425/029Jigs and dies

Definitions

  • This invention relates to a casting jig, and more particularly, to a jig for casting slabs into integral units having cores therein.
  • Glazed facing tile units are especially in demand for laboratory walls and partitions, foodhandlingl rooms and other areas where cleanliness and durability are to be combined with pleasing appearance.
  • the most desirable facing tile unit would be one which .could be used without other structural elements to form either an outside wall or an inside partition, and as ordinarily both exposed faces are desired to have glazed surfaces, a double-faced unit is required.
  • Double-faced units can be produced by glazing both sides of a single unit, but this ordinarily limits the units to a single surface texture on both sides, and more important, the irregular shrinkage resulting from the glazing process tends to alter the dimensions of the units so that both sides cannot be held to an exact tolerance.
  • the best wall construction made from these units is a smooth, accurate surface on one side and an uneven, jagged surface on the other side. This, of course, is very undesir- .able for most building purposes where both surfaces should be smooth.
  • the .only acceptable method of building tile walls having glazed surfaces on both sides is to use separate units on each side of the wall which costs approximately twice as much as a single width wall because of increased labor costs. Also, using two units the thickness of the wall is increased reducing the size of the rooms, and when thin units are used ⁇ to keep the thickness down to a minimum, they are extremely difiicult to lay, great care being necessary to hold them in position while mortaring.
  • the ideal but heretofore unobtainable individual glazed tile unit would be one having two glazed surfaces having tolerances within a standard range capable of use to form a wall of single unit thickness without additional structural elements and capable of being produced in different colorings and textures on the opposing surfaces.
  • the units should have cores which mate with the cores of adjacent units to provide the wall with coring for wiring, conduits, reinforcing rods or the like, and if possible, there should be coring running both vertically and horizontally.
  • the present invention provides a jig into which singlefaced slabs are placed opposite one another and alined by the jig. Spacing members are insertable between the slabs to hold them in position and to form with other elements of the jig the walls of a cavity into which a bonding material such as fast-setting grout may be poured to bond the slabs into an integral unit having vertical cores determined by the space occupied by the spacing members and horizontal cores determined by the level of the bonding material.
  • slabs of any texture or coloring can be .tates Patent O combined, and the slabs can be pre-selected so as to be within any desirable dimensional tolerance.
  • the general object of the present invention is to provide a new and improved casting jig.
  • Another object of the present invention is to provide a new and improved jig for casting slabs into an integral unit having cores therein.
  • a further object of the present invention is to provide a jig of the type described having spacing members which are insertable between the slabs to urge them against alining members.
  • Yet another object of the present invention is to provide a jig of the type described in the preceding paragraph wherein the spacing members are inflatable to hold the slabs in position and deatable to permit unobstructed removal from the jig.
  • Yet a further object of the present invention is to provide a jig as described, having alining members movable into engagement with the slabs to hold them during the casting, and movable out of engagement with the slabs to permit removal of the cast unit.
  • Still another o-bject of the present invention is to provide a jig as described herein with inflatable spacing members, each having a rod extending therein, through which air passes to inflate or deflate the spacing member, the rods having enlarged ends within the spacing members to insure deflation of the spacing members about the enlarged end to prevent the deflated spacing member to contact portions of the adjacent unit.
  • a still further object of the present invention is to provide a jig as described which forms a cavity between the slabs for receipt of bonding material which binds the slabs into an integral unit.
  • Yet another object of the present invention is to provide a jig wherein the spacing members provide vertical cores in the cast unit and the vertical cores are determined by the amount of the bonding material used.
  • a further object of the present invention is to provide a jig as described wherein unit is cast on a pallet to facilitate removal and handling of the unit after casting.
  • Fig. 1 is a side elevation View of one embodiment of the casting jig of the present invention
  • Fig. 2 is a horizontal sectional view taken along line 2 2 of Fig. l, the inatable bags being shown schematically by dot-dash lines;
  • Fig. 3 is a side elevational view of the device of Fig. l;
  • Fig. 4 is a partial side elevational view similar to Fig. 3, but with the elements in a different position;
  • Fig. 5 is a vertical sectional view taken along line 5-5 of Fig. 2;
  • Fig. 6 is a side elevational view partially in section of an inflatable spacing member of Fig. 1;
  • Fig. 7 is a horizontal sectional view taken along line 7-7 of Fig. 6;
  • Fig. 8 is a perspective view of an integral unit Ycast in the jig of Fig. 1;
  • Fig. 9 is an enlarged partial side elevational view of the locking mechanism shown in Fig. 3.
  • Fig. 10 is a bottom View of the center spacing members of the device of Fig. l.
  • the casting jig shown generally as 20, consists of a support 21 having a wooden base 22 for the support of a pallet 23 upon which slabs 24 are placed to be cast into integral units.
  • the support has upstanding sides 25 to which movable, aligning or side members 26 are attached for engagement with the slabs 24.
  • spacing members 27 are movably mounted for insertion between the slabs.
  • the spacing members 27 are attached to a rack 28 which is movably supported and guided by upstanding rods 29.
  • Air conduits 30 lead from controls 31 which control the inflation and dellation of the spacing members 27 by alternately introducing air under pressure to inflate the spacing members and evacuating the air to deate the spacing members.
  • these sides consist of channels 32 having vertical slots 33 to permit movement of the aligning member 26 illustrated in the drawings as lugs which are attached to hinged pfates 35.
  • These plates are attached to the top of the side channels 32 by means of hinges 36, and thus are movable outwardly away from the side channels.
  • Coil springs 37 are attached to the plates 35 and engage the side channels to urge the plates outwardly therefrom.
  • a locking mechanism 38 is provided to lock the plates 35 into engagement with the side channels 32.
  • This mechanism consists of a plate engaging link 39 having one end 40 pivotally attached to a flange 41 on the side 25, and the other end 39 contacting the plate 35. Adjacent the end 40, a locking link 42 is pivotally attached and extends outwardly for pivotal attachment to the locking handle 43.
  • the locking handle has one end 44 pivotally attached to the tlange 41.
  • the links are so arranged that when in a locked position, as shown in Fig. 3, the locking link 42 wou'd normally urge the operating handle downwardly as the spring urges the plate 35 away from the side channel 32. Thus the operating handle is prevented from moving upwardly, and the plate 35 is locked in the slab engaging position.
  • the aligning lugs 26 which extend from the hinged plates 35 through the slots 33 in the side channels are positioned so as to contact the slabs'24 and hold them in place for the casting of a unit having exact dimensional tolerances. This is accomplished by having center lugs 45 in contact with the faces of the slabs to control the thickness of the cast unit, and end lugs 46 in contact with the ends 47 of the slabs to provide a cast unit with ends perpendicular to the faces.
  • end lugs 46 are provided only at the outer ends of the jig, the inner ends of the slabs being aligned by two of the intlatable spacing members 27 as will be described below.
  • the spacing members 27 are vertically movable into and out of engagement with the slabs 24 and are bolted to the rack 28 to provide rigidity.
  • the rack consists of three horizontal bars 48 to which angle plates 49 are bolted, and it is from these angle plates that the spacing members depend.
  • the rack 28 is movably suspended from the rods 29 by wires 50 extending down from pulleys 51, and is guided in its vertical movement by engagement of three rollers 52 attached to each end of the rack.
  • the rollers are arranged with at least one of each set of rollers on opposite a side of the rod 29.
  • the rack construction and the means of moving the rack may be of any similar construction and still be within the purview of the present invention.
  • the wires 50 may be secured to counter-weights to facilitate movement of the rack.
  • the spacing members actually are plastic bags 53 having rectangular vertical and horizontal cross sections and are inatable.
  • the top of each plastic bag is hermetically sealed by bolting the top between clamping plates 54 having a resilient gasket 55 therebetween to insure a proper seal.
  • Extending through the plates and gasket is a hollow rod 57 having an open end 58 inside the bag and an intermediate opening 59 also inside the bag. This rod serves as a conduit through which air under pressure may pass to inate the bag and through which air may be evacuated from the bag to deflate the bag and create a vacuum therein so that the bag will collapse about the rod 57.
  • the open end 58 is enlarged as at 60 and is spaced above the bottom of the bag so as to prevent the bag from collapsing against the open end 58 before the bag has been thoroughly evacuated. Further, the rod and especially the enlarged end guide the collapse of the bag so that it will not collapse against the adjacent portions of the cast unit and will prevent obstruction of withdrawal of the bag, or possible damage to the cast unit when the bags are removed before the mortar has thoroughly hardened.
  • ten bags are utilized and are arranged with a single bag 62, two bags 63 and 64 spaced from the first bag, a combination of four bags 65, 66, 67 and 68 spaced from the two bags, two bags 69 and 70 spaced from the four bags, and finally the last single bag spaced from the preceding two bags.
  • the spacing of the bags provides cavities into which mortar may be poured with the bags adjacent the spaces forming sealed cavity walls when inflated.
  • Two of the central bags 66 and 67 of the four-bag combination are arranged so as to be spaced between adjacent slabs to properly space the units and thus extend outwardly between adjacent slabs.
  • a wooden block 72 is mounted in the center so that each bag has a side abutting the block thereby positioning each bag independently.
  • Air conduits 73 are attached to the rods 57 extending from the two central bags 66 and 67 and join to form a single conduit leading to the controls 31 for separate ination of the central bags.
  • Air conduits 75 extend from the rods 57 of the other bags 62, 63, 64, 65, 68, 69, 70 and 71 and are each joined to a pipe 76 from which a main conduit 77 extends to the controls 31.
  • the controls 31 consist of three valves.
  • the first valve 78 controls the introduction of air under pressure through the first air conduit 73 and into the central bags 66 and 67.
  • the second valve 79 controls the introduction of air under pressure into the other bags, and the third valve 80 controls the evacuation of all the bags.
  • the central bags can be inflated independently of the others bags, and all the bags can be evacuated simultaneously.
  • the jig is initially open with the bags or spacing members 62 through 71 withdrawn upwardly as shown in Fig. 3 and deflated and with the hinged plates 35 retracted horizontally away from the side channels 32 as shown in Fig. 4.
  • the pallet 23 is then slid onto the Wooden base 22 and slabs 24 are placed on the pallet adjacent and in front of the aligning lugs 26 as shown in phantom in Fig. 4.
  • the locking handle 43 is then forced downwardly to lock the hinged plates 35 against the side channels 32 so that the lugs 26 extend into engagement with the slabs 24 as shown in Fig. 3, the positions of the slabs being indicated by broken lines.
  • the rack 28 is then lowered so that the spacing members 27 are inserted between the slabs 24 in the position indicated by dotted lines in Fig. 3.
  • the first valve 78 is adjusted so as to inate the central bags 66 and 67 thereby spacing the adjacent slabs and urging them against the end lugs 46 for precise alignment.
  • the second valve 79 is then adjusted to inliate the other bags which urge the slabs 24 against the center lugs 45. Also when the bags are inflated, they form a seal between the slabs and sealingly abut the pallet 23 to form a cavity for the receipt of bonding material such as quicksetting grout which is poured into the cavities.
  • the lugs 26 and 45 do not come into cont-act with the grout, but rather, are located in the free space on the outside of the finished block. Therefore, there is no problem of moving the lugs away from the block.
  • the bags are evacuated and withdrawn, the plates 35 swing out and the finished unit 81 is removed on the pallet 23.
  • Fig. 8 illustrates a typical unit 81 cast in the jig of the present invention.
  • the unit has two glazed faces 82 provided by the two slabs 24 which are bonded together by the bonding material 83.
  • Vertical coring 84 has been provided by the spacing members 27 occupying a portion of the space between slabs and horizontal coring 85 can be 'accomplished as desired by controlling the amount of bonding material used to provide a space between the level of the bonding material and the top of the slabs.
  • the present invention provides a jig that can be utilized to cast slabs into integral units with channels running both vertically and horizontally, which is especially adaptable for casting slabs of glazed tile into double-faced units.
  • the opposite glazed surfaces of the units may be of different textures and colors and the dimensions of the unit can be held within standard tolerances so that the units can be used without other structural elements to form a two-faced wall with smooth surfaces on either side.
  • a jig for casting spaced slabs into integral units having cores therein comprising: a support having a horizontally disposed slab supporting base and side members having lugs spaced apart horizontally above said base to engage exterior surfaces of said slabs to align opposing slabs in upright laterally spaced positions, resilient spacing members insertable between said positions and opposing slabs and engaging opposed interior faces of the slabs to space the slabs and urge them outwardly against said side members, said slabs, spacing members and base forming a cavity therebetween for receipt of bonding material, and means for inserting said spacing members between the slabs, and for retracting the spacing members after the bonding material has bonded the slabs into an integral unit.
  • a jig for casting spaced slabs into integral units having cores therein comprising: a support having a slab supporting base and upstanding sides, side plates hingedly secured to said upstanding sides and having slab aligning lugs extending inwardly therefrom, means for swinging said plates into a slab engaging position wherein the lugs align the opposing slabs, resilient spacing members insertable between opposing slabs to space the slabs and urge them against the lugs, said slabs, spacing members and base forming a cavity therebetween for receipt of bonding material, and means for inserting said spacing members between the slabs and for retracting the spacing members after the bonding material has bonded the slabs into an integral unit.
  • a jig for casting spaced slabs into integral units having cores therein comprising: a support having a slab supporting base and upstanding sldes, side plates hingedly secured to said upstanding sides and having slab aligning lugs extending inwardly therefrom, spring means normally urging said plates and lugs out of engagement with said slabs, means for swinging the plates and lugs into a slab engaging position and locking the plates in said engaging position wherein the lugs align the opposing slabs, inliatable spacing members insertable between opposing slabs, means for inserting and retracting said spacing members, and means for inflating the spacing members while inserted between the slabs and deating prior to retraction, the inflated spacing members extending between opposing slabs to urge the slabs against the lugs, said inflated spacing members, side members and base forming a cavity therebetween for receipt of bonding material which bonds the slabs into an integral unit.
  • a jig for casting spaced slabs into integral units having cores therein comprising: a support having a slab supporting base and upstanding sides, side plates hingedly secured to said upstanding sides and having slab-aligning lugs extending inwardly therefrom, means for swinging said plates into a slab engaging position wherein the lugs align the opposing slabs, inflatable spacing members insertable between opposing slabs, means for inating said spacing members while inserted between the slabs including the introductions of air under pressure, said means including hollow rods extending into said spacing members, each said rod having an air hole within its associated spacing member and having an enlarged end within the spacing member shaped to serve as a guide against which the spacing member is dellated so as to be incontiguous with adjacent objects, the spacing members when inated extending between opposing slabs to urge the slabs against said aligning lugs, said inated spacing members, side members and supporting base forming a cavity therebetween for receipt of bonding material which bonds the slabs into an integral unit.
  • a support having a slab-supporting base and laterally spaced upstanding sides having opposed sets of slab-aligning lugs extending inwardly therefrom, means mounting at least one of said sets of lugs for movement toward the other set and into a slab-engaging position wherein both sets engage and align opposing slabs, resilient spacing members insertable between opposing slabs to space the slabs and urge them against the lugs, said slabs, spacing members and base forming a cavity therebetween for receipt of bonding material, and means for inserting said spacing members between the slabs and for retracting the spacing members after the bonding material has bonded the slabs into an integral unit.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Description

Dec. 20, 1960 l. D. oLsoN ET AL 2,954,820
, CASTING JIG Filed July l0, 1957 3 Sheets-Sheet 1 Mgg Dec. 20, 1960 l. D. OLSON ETAL 2,964,820
CASTING JIG 3 Sheets-Sheet 2 Filed July l0, 1957 by? v Dec. 20, 1960 l, D. OLSON ETAL 2,964,820
CASTING JIG 5 Sheets-Sheet 3 Filed July 10, 1957 lCASTIN G .HG
Irwin D. Olson, Lombard, Robert B. Taylor. Elmhurst, `Clarence B. Monk, Jr., Batavia, and John P. Wogulis, St. Charles, Ill., assgnors to Structural Clay Products Research Foundation Filed July 10, 1957, Ser. No. 671,107
6 Claims. (Cl. 25-121) This invention relates to a casting jig, and more particularly, to a jig for casting slabs into integral units having cores therein.
Of the many various materials adapted for use in building walls, one of the most desirable is glazed, structural clay tile. Glazed facing tile units are especially in demand for laboratory walls and partitions, foodhandlingl rooms and other areas where cleanliness and durability are to be combined with pleasing appearance.
The most desirable facing tile unit would be one which .could be used without other structural elements to form either an outside wall or an inside partition, and as ordinarily both exposed faces are desired to have glazed surfaces, a double-faced unit is required.
Double-faced units can be produced by glazing both sides of a single unit, but this ordinarily limits the units to a single surface texture on both sides, and more important, the irregular shrinkage resulting from the glazing process tends to alter the dimensions of the units so that both sides cannot be held to an exact tolerance. The best wall construction made from these units is a smooth, accurate surface on one side and an uneven, jagged surface on the other side. This, of course, is very undesir- .able for most building purposes where both surfaces should be smooth.
At the present, the .only acceptable method of building tile walls having glazed surfaces on both sides is to use separate units on each side of the wall which costs approximately twice as much as a single width wall because of increased labor costs. Also, using two units the thickness of the wall is increased reducing the size of the rooms, and when thin units are used `to keep the thickness down to a minimum, they are extremely difiicult to lay, great care being necessary to hold them in position while mortaring.
The ideal but heretofore unobtainable individual glazed tile unit would be one having two glazed surfaces having tolerances within a standard range capable of use to form a wall of single unit thickness without additional structural elements and capable of being produced in different colorings and textures on the opposing surfaces. Further, the units should have cores which mate with the cores of adjacent units to provide the wall with coring for wiring, conduits, reinforcing rods or the like, and if possible, there should be coring running both vertically and horizontally.
The present invention provides a jig into which singlefaced slabs are placed opposite one another and alined by the jig. Spacing members are insertable between the slabs to hold them in position and to form with other elements of the jig the walls of a cavity into which a bonding material such as fast-setting grout may be poured to bond the slabs into an integral unit having vertical cores determined by the space occupied by the spacing members and horizontal cores determined by the level of the bonding material.
With this jig, slabs of any texture or coloring can be .tates Patent O combined, and the slabs can be pre-selected so as to be within any desirable dimensional tolerance.
The general object of the present invention is to provide a new and improved casting jig.
Another object of the present invention is to provide a new and improved jig for casting slabs into an integral unit having cores therein.
A further object of the present invention is to provide a jig of the type described having spacing members which are insertable between the slabs to urge them against alining members.
Yet another object of the present invention is to provide a jig of the type described in the preceding paragraph wherein the spacing members are inflatable to hold the slabs in position and deatable to permit unobstructed removal from the jig.
Yet a further object of the present invention is to provide a jig as described, having alining members movable into engagement with the slabs to hold them during the casting, and movable out of engagement with the slabs to permit removal of the cast unit.
Still another o-bject of the present invention is to provide a jig as described herein with inflatable spacing members, each having a rod extending therein, through which air passes to inflate or deflate the spacing member, the rods having enlarged ends within the spacing members to insure deflation of the spacing members about the enlarged end to prevent the deflated spacing member to contact portions of the adjacent unit.
A still further object of the present invention is to provide a jig as described which forms a cavity between the slabs for receipt of bonding material which binds the slabs into an integral unit.
Yet another object of the present invention is to provide a jig wherein the spacing members provide vertical cores in the cast unit and the vertical cores are determined by the amount of the bonding material used.
A further object of the present invention is to provide a jig as described wherein unit is cast on a pallet to facilitate removal and handling of the unit after casting.
Other and further objects and advantages of the present invention are readily apparent from the following description and drawings in which:
Fig. 1 is a side elevation View of one embodiment of the casting jig of the present invention;
Fig. 2 is a horizontal sectional view taken along line 2 2 of Fig. l, the inatable bags being shown schematically by dot-dash lines;
Fig. 3 is a side elevational view of the device of Fig. l;
Fig. 4 is a partial side elevational view similar to Fig. 3, but with the elements in a different position;
Fig. 5 is a vertical sectional view taken along line 5-5 of Fig. 2;
Fig. 6 is a side elevational view partially in section of an inflatable spacing member of Fig. 1;
Fig. 7 is a horizontal sectional view taken along line 7-7 of Fig. 6;
Fig. 8 is a perspective view of an integral unit Ycast in the jig of Fig. 1;
Fig. 9 is an enlarged partial side elevational view of the locking mechanism shown in Fig. 3; and
Fig. 10 is a bottom View of the center spacing members of the device of Fig. l.
While this device is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail one specific embodiment, with the understanding that the present disclosure is to be considered as an exemplication of the principles .of the invention and is not intended to llimit the invention to the embodiment illustrated. The scope of the invention .will be pointed out in the appended claims.
Referring now to the drawings, the casting jig, shown generally as 20, consists of a support 21 having a wooden base 22 for the support of a pallet 23 upon which slabs 24 are placed to be cast into integral units. The support has upstanding sides 25 to which movable, aligning or side members 26 are attached for engagement with the slabs 24. Above the support 21, spacing members 27 are movably mounted for insertion between the slabs. The spacing members 27 are attached to a rack 28 which is movably supported and guided by upstanding rods 29. Air conduits 30 lead from controls 31 which control the inflation and dellation of the spacing members 27 by alternately introducing air under pressure to inflate the spacing members and evacuating the air to deate the spacing members.
Turning now to the sides 25 of the support 21, it is seen from the ligures in more detail that these sides consist of channels 32 having vertical slots 33 to permit movement of the aligning member 26 illustrated in the drawings as lugs which are attached to hinged pfates 35. These plates are attached to the top of the side channels 32 by means of hinges 36, and thus are movable outwardly away from the side channels. Coil springs 37 are attached to the plates 35 and engage the side channels to urge the plates outwardly therefrom.
A locking mechanism 38 is provided to lock the plates 35 into engagement with the side channels 32. This mechanism consists of a plate engaging link 39 having one end 40 pivotally attached to a flange 41 on the side 25, and the other end 39 contacting the plate 35. Adjacent the end 40, a locking link 42 is pivotally attached and extends outwardly for pivotal attachment to the locking handle 43. The locking handle has one end 44 pivotally attached to the tlange 41. The links are so arranged that when in a locked position, as shown in Fig. 3, the locking link 42 wou'd normally urge the operating handle downwardly as the spring urges the plate 35 away from the side channel 32. Thus the operating handle is prevented from moving upwardly, and the plate 35 is locked in the slab engaging position.
To unlock the locking mechanism, the locking handle 43 is moved upwardly until the locking link 42 is forced out of the locking position permitting the spring to urge the plate 35 away from side channel 32 as shown in Fig. 4. An enlarged view of the locking mechanism is shown in Fig. 9.
The aligning lugs 26 which extend from the hinged plates 35 through the slots 33 in the side channels are positioned so as to contact the slabs'24 and hold them in place for the casting of a unit having exact dimensional tolerances. This is accomplished by having center lugs 45 in contact with the faces of the slabs to control the thickness of the cast unit, and end lugs 46 in contact with the ends 47 of the slabs to provide a cast unit with ends perpendicular to the faces.
In the jig shown in the drawings, two units are cast simultaneously, and in the embodiment shown, end lugs 46 are provided only at the outer ends of the jig, the inner ends of the slabs being aligned by two of the intlatable spacing members 27 as will be described below.
The spacing members 27 are vertically movable into and out of engagement with the slabs 24 and are bolted to the rack 28 to provide rigidity. The rack consists of three horizontal bars 48 to which angle plates 49 are bolted, and it is from these angle plates that the spacing members depend. The rack 28 is movably suspended from the rods 29 by wires 50 extending down from pulleys 51, and is guided in its vertical movement by engagement of three rollers 52 attached to each end of the rack. The rollers are arranged with at least one of each set of rollers on opposite a side of the rod 29. The rack construction and the means of moving the rack may be of any similar construction and still be within the purview of the present invention. For instance the wires 50 may be secured to counter-weights to facilitate movement of the rack. An alternative would be to use a power winch of some sort.
As shown in the drawings, the spacing members actually are plastic bags 53 having rectangular vertical and horizontal cross sections and are inatable. The top of each plastic bag is hermetically sealed by bolting the top between clamping plates 54 having a resilient gasket 55 therebetween to insure a proper seal. Extending through the plates and gasket is a hollow rod 57 having an open end 58 inside the bag and an intermediate opening 59 also inside the bag. This rod serves as a conduit through which air under pressure may pass to inate the bag and through which air may be evacuated from the bag to deflate the bag and create a vacuum therein so that the bag will collapse about the rod 57. The open end 58 is enlarged as at 60 and is spaced above the bottom of the bag so as to prevent the bag from collapsing against the open end 58 before the bag has been thoroughly evacuated. Further, the rod and especially the enlarged end guide the collapse of the bag so that it will not collapse against the adjacent portions of the cast unit and will prevent obstruction of withdrawal of the bag, or possible damage to the cast unit when the bags are removed before the mortar has thoroughly hardened.
In the embodiment shown in the drawings, ten bags are utilized and are arranged with a single bag 62, two bags 63 and 64 spaced from the first bag, a combination of four bags 65, 66, 67 and 68 spaced from the two bags, two bags 69 and 70 spaced from the four bags, and finally the last single bag spaced from the preceding two bags. When the bags are inserted into the jig, the spacing of the bags provides cavities into which mortar may be poured with the bags adjacent the spaces forming sealed cavity walls when inflated. Two of the central bags 66 and 67 of the four-bag combination are arranged so as to be spaced between adjacent slabs to properly space the units and thus extend outwardly between adjacent slabs. To properly position the bags in the combination of the four bags for precise displacement when inflated, a wooden block 72 is mounted in the center so that each bag has a side abutting the block thereby positioning each bag independently.
Air conduits 73 are attached to the rods 57 extending from the two central bags 66 and 67 and join to form a single conduit leading to the controls 31 for separate ination of the central bags. Air conduits 75 extend from the rods 57 of the other bags 62, 63, 64, 65, 68, 69, 70 and 71 and are each joined to a pipe 76 from which a main conduit 77 extends to the controls 31.
The controls 31 consist of three valves. The first valve 78 controls the introduction of air under pressure through the first air conduit 73 and into the central bags 66 and 67. The second valve 79 controls the introduction of air under pressure into the other bags, and the third valve 80 controls the evacuation of all the bags. With this arrangement, the central bags can be inflated independently of the others bags, and all the bags can be evacuated simultaneously.
In operation, the jig is initially open with the bags or spacing members 62 through 71 withdrawn upwardly as shown in Fig. 3 and deflated and with the hinged plates 35 retracted horizontally away from the side channels 32 as shown in Fig. 4. The pallet 23 is then slid onto the Wooden base 22 and slabs 24 are placed on the pallet adjacent and in front of the aligning lugs 26 as shown in phantom in Fig. 4. The locking handle 43 is then forced downwardly to lock the hinged plates 35 against the side channels 32 so that the lugs 26 extend into engagement with the slabs 24 as shown in Fig. 3, the positions of the slabs being indicated by broken lines. The rack 28 is then lowered so that the spacing members 27 are inserted between the slabs 24 in the position indicated by dotted lines in Fig. 3. After the spacing members are fully inserted, the first valve 78 is adjusted so as to inate the central bags 66 and 67 thereby spacing the adjacent slabs and urging them against the end lugs 46 for precise alignment. The second valve 79 is then adjusted to inliate the other bags which urge the slabs 24 against the center lugs 45. Also when the bags are inflated, they form a seal between the slabs and sealingly abut the pallet 23 to form a cavity for the receipt of bonding material such as quicksetting grout which is poured into the cavities. The lugs 26 and 45 do not come into cont-act with the grout, but rather, are located in the free space on the outside of the finished block. Therefore, there is no problem of moving the lugs away from the block. Upon setting of the grout, the bags are evacuated and withdrawn, the plates 35 swing out and the finished unit 81 is removed on the pallet 23.
Fig. 8 illustrates a typical unit 81 cast in the jig of the present invention. The unit has two glazed faces 82 provided by the two slabs 24 which are bonded together by the bonding material 83. Vertical coring 84 has been provided by the spacing members 27 occupying a portion of the space between slabs and horizontal coring 85 can be 'accomplished as desired by controlling the amount of bonding material used to provide a space between the level of the bonding material and the top of the slabs.
In order to make this jig commercially vsuccessful it is necessary that a very fast setting grout be used such as that of the co-pending application No. 458,512 led September 27, 1954, now abandoned. With that particular grout using a combination of Portland cement and Luminite with little or no sand, an initial setting time of ve to six minutes is possible, after which the unit can be removed on the pallet 23 and stored for further setting. Thus it is obvious that with a bank of a multitude of jigs designed to cast a multitude of units, mass production at low cost can be easily accomplished.
Therefore, the present invention provides a jig that can be utilized to cast slabs into integral units with channels running both vertically and horizontally, which is especially adaptable for casting slabs of glazed tile into double-faced units. The opposite glazed surfaces of the units may be of different textures and colors and the dimensions of the unit can be held within standard tolerances so that the units can be used without other structural elements to form a two-faced wall with smooth surfaces on either side.
We claim as our invention:
1. A jig for casting spaced slabs into integral units having cores therein, the jig comprising: a support having a horizontally disposed slab supporting base and side members having lugs spaced apart horizontally above said base to engage exterior surfaces of said slabs to align opposing slabs in upright laterally spaced positions, resilient spacing members insertable between said positions and opposing slabs and engaging opposed interior faces of the slabs to space the slabs and urge them outwardly against said side members, said slabs, spacing members and base forming a cavity therebetween for receipt of bonding material, and means for inserting said spacing members between the slabs, and for retracting the spacing members after the bonding material has bonded the slabs into an integral unit.
2. A jig for casting spaced slabs into integral units having cores therein, the jig comprising: a support having a slab supporting base and upstanding sides, side plates hingedly secured to said upstanding sides and having slab aligning lugs extending inwardly therefrom, means for swinging said plates into a slab engaging position wherein the lugs align the opposing slabs, resilient spacing members insertable between opposing slabs to space the slabs and urge them against the lugs, said slabs, spacing members and base forming a cavity therebetween for receipt of bonding material, and means for inserting said spacing members between the slabs and for retracting the spacing members after the bonding material has bonded the slabs into an integral unit.
3. A jig for casting spaced slabs into integral units having cores therein, the jig comprising: a support having a slab supporting base and upstanding sldes, side plates hingedly secured to said upstanding sides and having slab aligning lugs extending inwardly therefrom, spring means normally urging said plates and lugs out of engagement with said slabs, means for swinging the plates and lugs into a slab engaging position and locking the plates in said engaging position wherein the lugs align the opposing slabs, inliatable spacing members insertable between opposing slabs, means for inserting and retracting said spacing members, and means for inflating the spacing members while inserted between the slabs and deating prior to retraction, the inflated spacing members extending between opposing slabs to urge the slabs against the lugs, said inflated spacing members, side members and base forming a cavity therebetween for receipt of bonding material which bonds the slabs into an integral unit.
4. A jig for casting spaced slabs into integral units having cores therein, the jig comprising: a support having a slab supporting base and upstanding sides, side plates hingedly secured to said upstanding sides and having slab-aligning lugs extending inwardly therefrom, means for swinging said plates into a slab engaging position wherein the lugs align the opposing slabs, inflatable spacing members insertable between opposing slabs, means for inating said spacing members while inserted between the slabs including the introductions of air under pressure, said means including hollow rods extending into said spacing members, each said rod having an air hole within its associated spacing member and having an enlarged end within the spacing member shaped to serve as a guide against which the spacing member is dellated so as to be incontiguous with adjacent objects, the spacing members when inated extending between opposing slabs to urge the slabs against said aligning lugs, said inated spacing members, side members and supporting base forming a cavity therebetween for receipt of bonding material which bonds the slabs into an integral unit.
5. The jig of claim 4 wherein a unit transporting pallet is slidable onto said slab supporting base for casting of said unit thereon and upon which the cast unit is removed from the jig.
6. In a jig for casting spaced slabs into integral units having cores therein, the combination of a support having a slab-supporting base and laterally spaced upstanding sides having opposed sets of slab-aligning lugs extending inwardly therefrom, means mounting at least one of said sets of lugs for movement toward the other set and into a slab-engaging position wherein both sets engage and align opposing slabs, resilient spacing members insertable between opposing slabs to space the slabs and urge them against the lugs, said slabs, spacing members and base forming a cavity therebetween for receipt of bonding material, and means for inserting said spacing members between the slabs and for retracting the spacing members after the bonding material has bonded the slabs into an integral unit.
References Cited in the tile of this patent UNITED STATES PATENTS 20,718 Maddock et al Feb. 17, 1903 813,439 Landon Feb. 27, 1906 875,983 Clayton Ian. 7, 1908 1,142,341 McNeil Iune 8, 1915 1,149,637 Daley Aug. 10, 1915 1,634,047 Smith June 28, 1927 2,203,694 Morin et al. June 11, 1940 2,668,999 Baechler Feb. 16, 1954 2,671,941 Fabian Mar. 16, 1954 2,741,821 Findley Apr. 17, 1956 2,764,798 Huff Oct. 2, 1956 2,781,554 Robinson -.--...-.u Feb. 19, 1957
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Publication number Priority date Publication date Assignee Title
US3035324A (en) * 1960-09-20 1962-05-22 James C Milne Method of making mausoleum structures
US3090093A (en) * 1960-08-25 1963-05-21 Leonard D Long Apparatus for making pre-cast cored building blocks
US3155751A (en) * 1960-11-07 1964-11-03 Whirlpool Co Method of making an insulated structure
US4543052A (en) * 1984-08-21 1985-09-24 Stevens Garry B Apparatus for insulated building block

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US813439A (en) * 1905-03-08 1906-02-27 Landon Cement Product Company Mold.
US875983A (en) * 1907-05-20 1908-01-07 John B Clayton Concrete construction.
US1142341A (en) * 1910-02-09 1915-06-08 John Douglas Company Apparatus for molding clay or similar material.
US1149637A (en) * 1914-01-26 1915-08-10 Denis William Daley Support for moldboards.
US1634047A (en) * 1925-06-04 1927-06-28 George I Smith Mold
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US2668999A (en) * 1949-12-15 1954-02-16 Bachler Joseph Means for making toy structural units
US2671941A (en) * 1952-03-03 1954-03-16 Emil L Fabian Form for casting concrete building blocks
US2741821A (en) * 1953-05-18 1956-04-17 Deon C Findley Form brace
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US2781554A (en) * 1956-03-02 1957-02-19 Tile Council Of America Method and apparatus for making tile panels

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Publication number Priority date Publication date Assignee Title
US720718A (en) * 1901-02-04 1903-02-17 William Edward Maddock Apparatus for pressing hollow ware.
US813439A (en) * 1905-03-08 1906-02-27 Landon Cement Product Company Mold.
US875983A (en) * 1907-05-20 1908-01-07 John B Clayton Concrete construction.
US1142341A (en) * 1910-02-09 1915-06-08 John Douglas Company Apparatus for molding clay or similar material.
US1149637A (en) * 1914-01-26 1915-08-10 Denis William Daley Support for moldboards.
US1634047A (en) * 1925-06-04 1927-06-28 George I Smith Mold
US2203694A (en) * 1937-02-15 1940-06-11 Whitehall Patents Corp Separable fastener element and the method of making the same
US2668999A (en) * 1949-12-15 1954-02-16 Bachler Joseph Means for making toy structural units
US2671941A (en) * 1952-03-03 1954-03-16 Emil L Fabian Form for casting concrete building blocks
US2741821A (en) * 1953-05-18 1956-04-17 Deon C Findley Form brace
US2764798A (en) * 1953-08-24 1956-10-02 John P Huff Concrete form
US2781554A (en) * 1956-03-02 1957-02-19 Tile Council Of America Method and apparatus for making tile panels

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3090093A (en) * 1960-08-25 1963-05-21 Leonard D Long Apparatus for making pre-cast cored building blocks
US3035324A (en) * 1960-09-20 1962-05-22 James C Milne Method of making mausoleum structures
US3155751A (en) * 1960-11-07 1964-11-03 Whirlpool Co Method of making an insulated structure
US4543052A (en) * 1984-08-21 1985-09-24 Stevens Garry B Apparatus for insulated building block

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