Continuous tunnel kiln for curing molded concrete products

Claim 2

In a system for curing molded concrete products such as green concrete blocks supported on pallets; a circular tunnel structure having inner, outer and top walls defining an essentially closed passageway except for ends at which loading and unloading can be accomplished; a carousel, comprising circumferentially spaced carriers, with vertically spaced, generally radially extending shelf members for supporting the products, disposed for indexing rotary travel in said passageway; said carriers having a substantially imperforate inner and outer end wall, a substantially imperforate bottom wall, a substantially imperforate radial wall, and a substantially imperforate top wall, but being sidewisely open; circumferentially spaced groups of circumferentially spaced resilient wiper blades mounted by said tunnel structure along the top, bottom, and inner and outer ends of the pathway of said carriers to extend into the path of said carriers and form sealed compartments between said groups as a result of carriers being stopped in indexed position at a series of circumferentially spaced locations in said tunnel structure, radially opposite said groups, said groups of blades being spaced apart a distance equal to a multiple of the distance between the radial walls of said carriers; means for introducing curing steam into certain compartments; and means for indexing the carousel in predetermined increments to always dispose carriers radially opposite said wiper blades at said spaced locations.

Claim 3

The system as set forth in claim 1 wherein said groups are all spaced apart a distance equal to a multiple of the distance between said radial walls.

Claim 4

The system as set forth in claim 1 in which said groups are of a circumferential extent greater than the circumferential extent of said end walls.

Claim 5

The system as set forth in claim 1 in which the circumferential spacing between blades is less than the circumferential extent of said end walls.

Claim 6

The system as set forth in claim 1 in which means is provided for recirculating the atmosphere in at least certain compartments and introducing a fluid to provide steam into the atmosphere being recirculated.

Claim 7

The system as set forth in claim 5 in which the fluid is steam.

Claim 8

The system as set forth in claim 5 in which the fluid is water.

Claim 9

The system as set forth in claim 6 in which said recirculating means comprises a fan and ducting connected with said tunnel enclosure by a supply duct and a return duct and wherein said fluid is introduced countercurrent to the sUpply flow.

Claim 10

The system as set forth in claim 8 in which heated fluid-filled tubes are provided in said ducting past which said atmosphere is moved to the supply duct and a fluid supply nozzle extends into said supply duct with nozzle openings facing in a direction to introduce the fluid in a counterflow direction.

Claim 11

The system as set forth in claim 1 in which said carousel comprises a circular chassis made up of joined arcuate sections comprising inner and outer circumferentially extending rails joined by radially extending members forming circumferentially spaced wedge shaped rack mounts, said carriages comprise upstanding racks, with vertically spaced shelves, fixed on said mounts, and rollers are mounted on said tunnel structure to engage and support said chassis for travel in its rotary pathway.

Claim 12

The system as set forth in claim 10 in which thrust blocks are provided in circumferentially spaced position on said sections circumferentially intermediate said rack mounts and radially between said inner and outer rails, and said means for indexing the carousel includes a traveling dog for engaging said thrust blocks and moving the carousel.

Claim 13

The system as set forth in claim 11 in which said arcuate sections have radially extending end rails and thrust blocks are also provided approximately beneath them.

Claim 14

The system as set forth in claim 11 in which a guide plate having an arcuate opening with inner and outer marginal sides conforming to arcs taken from the axis of revolution of the carousel is provided on said tunnel structure beneath the path of said carousel and a carriage mounting said dog moves in a reciprocatory path along said marginal sides.

Claim 15

The system as set forth in claim 13 in which said dog is eccentrically mounted on said carriage to be gravity returned from a tilted, inoperative position to an operative upright position in which it can engage and push a thrust block.

Claim 16

In a system for curing molded concrete products such as green concrete blocks supported on pallets; a circular tunnel structure having inner, outer and top walls defining an essentially closed passageway except for ends at which loading and unloading can be accomplished; a carousel, comprising circumferentially spaced carriers, with vertically spaced generally radially extending shelf members for supporting the products, disposed for indexing rotary travel in said passageway; said carriers having substantially imperforate inner and outer end walls, a substantially imperforate bottom wall, a substantially imperforate radial wall, and a substantially imperforate top wall, but being sidewisely open; circumferentially spaced groups of seals mounted to form sealed compartments between said groups as a result of carriers being stopped in indexed position at a series of circumferentially spaced locations in said tunnel; means for introducing heated air with entrained steam into certain compartments, recirculating it, and entraining sufficient added steam is the recirculated flow to maintain a predetermined humidity level in said compartments prior to reintroducing it to said compartments; and means for indexing the carousel in increments to dispose carriers radially opposite said seals at said spaced locations.

Claim 17

In a system for curing molded concrete products such as green concrete blocks supported on pallets; a circular tunnel structure having inner, outer and top walls defining an essentially closed passageway except for ends at which loading and unloading can be accomplished; a carousel, comprising circumferentially spaced carriers, with vertically spaced generally radially extending shelf members for supporting the products, disposed for indexing rotary travel in said passageway; said carriers having substantially imperforate inner and outer end walls, a substantially imperforate bottom wall, a substantially imperforate radial wall, and a substantially imperforate top wall, but being sidewisely open; circumferentially spaced groups of seals mounted to form sealed compartments between said groups as a result of carriers being stopped in indexed position at a series of circumferentially spaced locations in said tunnel; means for introducing heated air with entrained steam into certain compartments, recirculating it, and entraining sufficient added steam is the recirculated flow to maintain a predetermined humidity level in said compartments prior to reintroducing it to said compartments; and means for indexing the carousel in increments to dispose carriers radially opposite said seals at said spaced locations.

Claim 18

The system as set forth in claim 15 in which said means for introducing heated air with entrained steam includes a fan and ducting housing heating elements and connected with a supply duct leading to certain compartments and a return duct leading therefrom, and a fluid-filled nozzle to entrain steam in the hot air circulated by the fan is disposed to direct the fluid in a direction counterflow to the air flow.

Claim 19

The system of claim 15 in which said means for introducing heated air with entrained steam includes a fan and ducting housing heating elements connected with a supply duct leading to said certain compartments and a return duct leading therefrom, a fluid dispensing member is provided to entrain steam in the heaTed air, and means is included for sensing the humidity and temperature in said compartments and operating said fan and fluid dispensing member accordingly, said latter means including a circuit which operates said fluid dispensing member only when said fan is operating.

Claim 20

In a system for curing molded concrete products such as green concrete blocks supported on pallets; a circular tunnel structure having inner, outer and top walls defining an essentially closed passageway except for ends at which loading and unloading can be accomplished; support rollers mounted in the bottom of said tunnel structure around the circumference thereof; a carousel, comprising a circular chassis made up of joined arcuate sections comprising inner and outer circumferentially extending rails joined by radially extending members forming circumferentially spaced rack mounts and circumferentially spaced rack carriers, with vertically spaced generally radially extending shelf members for supporting the products secured on said chassis over said mounts, disposed for indexing rotary travel in said passageway on said support rollers; said carriers having substantially imperforate inner and outer end walls, a substantially imperforate bottom wall, a substantially imperforate radial wall, and a substantially imperforate top wall, but being sidewisely open; circumferentially spaced groups of seals mounted to form sealed compartments between said groups as a result of carriers being stopped in indexed position at a series of circumferentially spaced locations in said tunnel; means for providing heated air with entrained steam in certain compartments; and means for indexing the carousel in increments to dispose carriers radially opposite said seals at said spaced locations.

Claim 21

In a system for curing molded concrete products such as green concrete blocks supported on pallets; a circular tunnel structure having inner, outer and top walls defining an essentially closed passageway except for ends at which loading and unloading can be accomplished; support rollers mounted in the bottom of said tunnel structure around the circumference thereof; a carousel, comprising a circular chassis made up of joined arcuate sections comprising inner and outer circumferentially extending rails joined by radially extending members forming circumferentially spaced rack mounts and circumferentially spaced rack carriers, with vertically spaced generally radially extending shelf members for supporting the products secured on said chassis over said mounts, disposed for indexing rotary travel in said passageway on said support rollers; said carriers having substantially imperforate inner and outer end walls, a substantially imperforate bottom wall, a substantially imperforate radial wall, and a substantially imperforate top wall, but being sidewisely open; circumferentially spaced groups of seals mounted to form sealed compartments between said groups as a result of carriers being stopped in indexed position at a series of circumferentially spaced locations in said tunnel; means for providing heated air with entrained steam in certain compartments; and means for indexing the carousel in increments to dispose carriers radially opposite said seals at said spaced locations.

Claim 22

The system as set forth in claim 18 in which thrust receiving members are provided in circumferentially spaced position beneath said chassis circumferentially intermediate said rack mounts; and said indexing means is operated to engage successive thrust receiving members.

Claim 23

In a system for curing molded concrete products such as green concrete blocks supported on pallets; a circular tunnel structure having inner, outer and top walls defining an essentially closed passageway except for ends at which loading and unloading can be accomplished; a carousel, comprising circumferentially spaced carriers, with vertically spaced generally radially extending shelf members for supporting the products, disposed for indexing rotary travel in said passageway; said carriers having substantially imperforate inner and outer end walls, a substantially imperforate bottom wall, a substantially imperforate radial wall, and a substantially imperforate top wall, but being sidewisely open; circumferentially spaced groups of seals mounted to form sealed compartments between said groups as a result of carriers being stopped in indexed position at a series of circumferentially spaced locations in said tunnel; means for providing heating air with entrained steam in certain compartments; a guide plate having arcuate means providing a guide wall, conforming to an arc taken from the axis of revolution of the carousel mounted beneath the path thereof; dog means for indexing the carousel in increments to dispose carriers radially opposite said seals at said spaced locations; and a carriage mounting said dog means for travel in a reciprocatory path along said guide wall; said dog means being eccentrically mounted on said carriage to be gravity returned from a tilted inoperative position to an operative pushing position in which it engages and pushes said carousel.

Claim 24

In a system for curing molded concrete products such as green concrete blocks supported on pallets; a circular tunnel structure having inner, outer and top walls defining an essentially closed passageway except for ends at which loading and unloading can be accomplished; a carousel, comprising circumferentially spaced carriers, with vertically spaced generally radially extending shelf members for supporting the products, disposed for indexing rotary travel in said passageway; said carriers having substantially imperforate inner and outer end walls, a substantially imperforate bottom wall, a substantially imperforate radial wall, and a substantially imperforate top wall, but being sidewisely open; circumferentially spaced groups of seals mounted to form sealed compartments between said groups as a result of carriers being stopped in indexed position at a series of circumferentially spaced locations in said tunnel; means for providing heating air with entrained steam in certain compartments; a guide plate having arcuate means providing a guide wall, conforming to an arc taken from the axis of revolution of the carousel mounted beneath the path thereof; dog means for indexing the carousel in increments to dispose carriers radially opposite said seals at said spaced locations; and a carriage mounting said dog means for travel in a reciprocatory path along said guide wall; said dog means being eccentrically mounted on said carriage to be gravity returned from a tilted inoperative position to an operative pushing position in which it engages and pushes said carousel.

Claim 25

In a system for curing molded concrete products such as green concrete blocks supported on pallets; a circular tunnel structure having inner, outer and top walls defining an essentially closed passageway except for ends at which loading and unloading can be accomplished; a carousel, comprising a circUlar chassis comprising inner and outer circumferentially extending wear rails providing circumferentially spaced rack mounts and circumferentially spaced rack carriers, with vertically spaced generally radially extending shelf members for supporting the products secured on said chassis over said mounts, disposed for rotary travel in said passageway; said carriers having substantially imperforate inner and outer end walls, a substantially imperforate bottom wall, a substantially imperforate radial wall, and a substantially imperforate top wall, but being sidewisely open; a radially inner and outer series of circumferentially spaced roller structures receiving said wear rails and mounting said carousel and rack carriers for travel within said tunnel structure; said roller structure comprising fixed base mounts and rollers mounted for restricted universal pivoting movment thereon to self-align with said wear rails; means to form sealed compartments between said rack carriers when said carriers are stopped at a series of circumferentially spaced locations in said tunnel; means for indexing said carousel in rotary increments of travel; and means for providing heated air with entrained steam in certain compartments.

Claim 26

In a system for curing molded concrete products such as green concrete blocks supported on pallets; a circular tunnel structure having inner, outer and top walls defining an essentially closed passageway except for ends at which loading and unloading can be accomplished; a carousel, comprising a circUlar chassis comprising inner and outer circumferentially extending wear rails providing circumferentially spaced rack mounts and circumferentially spaced rack carriers, with vertically spaced generally radially extending shelf members for supporting the products secured on said chassis over said mounts, disposed for rotary travel in said passageway; said carriers having substantially imperforate inner and outer end walls, a substantially imperforate bottom wall, a substantially imperforate radial wall, and a substantially imperforate top wall, but being sidewisely open; a radially inner and outer series of circumferentially spaced roller structures receiving said wear rails and mounting said carousel and rack carriers for travel within said tunnel structure; said roller structure comprising fixed base mounts and rollers mounted for restricted universal pivoting movment thereon to self-align with said wear rails; means to form sealed compartments between said rack carriers when said carriers are stopped at a series of circumferentially spaced locations in said tunnel; means for indexing said carousel in rotary increments of travel; and means for providing heated air with entrained steam in certain compartments.

Claim 27

The system defined in claim 21 wherein said means to form sealed compartments between said carriers comprises circumferentially spaced groups of circumferentially spaced resilient wiper blades mounted by said tunnel structure along the top, bottom, and inner and outer ends of the pathways of said rack carriers to extend into the path of said carriers and form sealed compartments between said groups as a result of carriers being stopped in indexed position at a series of circumferentially spaced locations in said tunnel structure, radially opposite said groups, said groups of blades being spaced apart a distance equal to a multiple of the distance between the radial walls of said carriers.

Claim 28

The system defined in claim 21 wherein said base mounts include a first pivot and a pivot limiting surface; and said rollers are mounted on said pivot on an intermediate frame carrying a second pivot disposed perpendicularly to said first pivot and incorporating a roller frame mount on said second pivot journaling a roller; said base mount including also pivot limiting surface for said intermediate frame mount.

Claim 29

The system defined in claim 23 wherein said roller frame mount journals a pair of rollers, one on either side circumferentially of said second pivot; said second pivot comprising a radially extending pin means.

Claim 30

The system defined in claim 24 wherein said first pivot comprises a generally circumferentially extending pin.

Claim 31

The system defined in claim 21 wherein said wear rails include strips of greater Brinell hardness than said wheels, for riding on said wheels.