Methods of demolding building products from a mold

Abstract

A demolding apparatus for removing molded building products from a mold has a conveyor assembly to advance the mold in a machine direction. A removal mechanism contacts a dislodged portion of the molded building product and applies a dislodging force to the dislodged portion of the molded building product.

1 .- 31 . (canceled) 
     
     
         32 . A method for removing a molded building product from a mold comprising:
 advancing a the mold on a conveyor assembly configured to advance the mold in a horizontal machine direction;   flexing the mold around an ejection roll to partially dislodge the building product from the mold; and   applying a dislodging force to a dislodged portion of the molded building product.   
     
     
         33 . The method of  claim 32 , wherein the mold is advanced in a continuous manner. 
     
     
         34 . The method of  claim 32 , further comprising: gripping a leading edge of the mold with a gripping mechanism to flex the mold around the ejection roll. 
     
     
         35 . The method of  claim 34 , further comprising: flexing the mold at an angle of at least about 100° from a horizontal planar position in order to partially dislodge the molded building product from the mold. 
     
     
         36 . The method of  claim 32 , further comprising the steps of: pouring concrete into the mold and curing the concrete prior to the step of advancing the mold on the conveyer assembly. 
     
     
         37 . The method of  claim 32 , wherein the removal mechanism includes an engagement member mounted in a cross-direction to the machine direction, the engagement member being configured to exert the dislodging force on the dislodged portion of the molded building product in a direction generally away from the mold. 
     
     
         38 . The method of  claim 32 , wherein the mold is elastomeric. 
     
     
         39 . The method of  claim 32 , wherein the molded building product comprises a plurality of rigid concrete stones. 
     
     
         40 . The method of  claim 32 , further comprising the steps of:
 releasably clamping the mold to the conveyor with a clamp prior to the step of flexing the mold, and   releasing the clamp after the step of applying the dislodging force.   
     
     
         41 . A method for removing a molded building product from a mold comprising:
 structuring a conveyor assembly configured to continuously advance the mold in a machine direction;   advancing the mold in the machine direction toward a curved portion of the conveyor;   directing the mold around the curved portion of the conveyor, wherein the curved portion is structured to cause the mold to follow the curve, and subsequently to direct the mold in a reverse machine direction;   dislodging a portion of the molded building product as the mold moves around the curved portion; and a removal mechanism configured to contact the dislodged portion of the molded building product and to apply an intermittent dislodging force to the dislodged portion of the molded building product while the reminder of the molded building product remains in the mold; and   stripping the mold from a leading edge of the molded building product to a trailing edge thereof, whereby the molded building product is completely removed from the mold.   
     
     
         42 . The method of  claim 41 , further comprising the steps of: pouring concrete into the mold and curing the concrete prior to the step of advancing the mold on the conveyer assembly. 
     
     
         43 . The method of  claim 42 , further comprising the steps of:
 releasably clamping the mold to the conveyor with a clamp prior to the step of flexing the mold, and   releasing the clamp after the step of removing the building product from the mold.   
     
     
         44 . The method of  claim 43 , further comprising the step of:
 inverting the mold so the building product is supported downwardly from the mold prior to the step of directing the mold around the curved portion of the conveyor.