US 9,808,957 B2
Mould filling method
Ronald J. Scherer, Crossville, TN (US); Leonard Browning, Aurora, IL (US); Robert J. Lundell, Stillwater, MN (US); and Steven E. Hinde, New Hartford, IA (US)
Assigned to Oldcastle Architectural, Inc., Atlanta, GA (US)
Appl. No. 13/575,120
Filed by Ronald J. Scherer, Crossville, TN (US); Leonard Browning, Aurora, IL (US); Robert J. Lundell, Stillwater, MN (US); and Steven E. Hinde, New Hartford, IA (US)
PCT Filed Jan. 21, 2011, PCT No. PCT/US2011/021973
§ 371(c)(1), (2), (4) Date Nov. 6, 2012,
PCT Pub. No. WO2011/094118, PCT Pub. Date Aug. 4, 2011.
Claims priority of provisional application 61/298,323, filed on Jan. 26, 2010.
Prior Publication US 2013/0049260 A1, Feb. 28, 2013
Int. Cl. B28B 13/02 (2006.01); B28B 1/29 (2006.01)
CPC B28B 1/29 (2013.01) [B28B 13/023 (2013.01); B28B 13/0255 (2013.01); B28B 13/0295 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A method of filling a mould with a settable material using an apparatus that includes the mould comprising at least a first cavity and a second cavity, each cavity being open to a top face of the mould, a scraper comprising at least a plurality of displaceable segments, and a mechanism that produces selective upward displacement of at least one segment of the scraper while simultaneously not displacing other segments of the scraper, the method comprising:
over filling the first cavity and the second cavity with the settable material, the first cavity being smaller than the second cavity;
moving the scraper across the top face of the mould;
upwardly displacing at least one first segment as the first segment passes over the first cavity while simultaneously not upwardly displacing at least one second segment as the second segment passes over the second cavity so that a height of a bottom edge of the first segment is above a height of a bottom edge of the second segment; and
achieving a desired material density and thickness of the settable material in the first cavity and the second cavity by a selective use of vibration or tamping or both.