U.S. patent application number 12/138566 was filed with the patent office on 2008-12-18 for mold box and method of manufacturing a block.
This patent application is currently assigned to KEYSTONE RETAINING WALL SYSTEMS, INC.. Invention is credited to Robert A. MacDonald.
Application Number | 20080307740 12/138566 |
Document ID | / |
Family ID | 40020182 |
Filed Date | 2008-12-18 |
United States Patent
Application |
20080307740 |
Kind Code |
A1 |
MacDonald; Robert A. |
December 18, 2008 |
MOLD BOX AND METHOD OF MANUFACTURING A BLOCK
Abstract
The present invention relates a mold box method of manufacturing
a block, and a wall block with a stepped-back strata and ledges
imprinted on one or more faces of the block. A mold box is provided
with a block face liner that is machine cut to create a particular
strata and ledge pattern that is widest at the top of the liner and
steps back over a plurality of planes to a narrower width at the
bottom of the liner. Masonry material is allowed to form in the
mold box around the liner to produce the strata and ledges imprint
onto one or more faces of the block. The invention also relates to
the mold box, multiple embodiments of the block face liner with
differing strata and ledge patterns, and to blocks formed in the
mold box and methods of constructing walls with the blocks.
Inventors: |
MacDonald; Robert A.;
(Plymouth, MN) |
Correspondence
Address: |
POPOVICH, WILES & O'CONNELL, PA;650 THIRD AVENUE SOUTH
SUITE 600
MINNEAPOLIS
MN
55402
US
|
Assignee: |
KEYSTONE RETAINING WALL SYSTEMS,
INC.
Bloomington
MN
|
Family ID: |
40020182 |
Appl. No.: |
12/138566 |
Filed: |
June 13, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60944177 |
Jun 15, 2007 |
|
|
|
Current U.S.
Class: |
52/604 ; 249/160;
264/299 |
Current CPC
Class: |
B28B 3/06 20130101; B28B
7/366 20130101; E04B 2002/0269 20130101; B28B 7/24 20130101; E04B
2002/0213 20130101; E04B 2002/0226 20130101; E04C 1/395 20130101;
B28B 7/007 20130101; E02D 29/025 20130101; E02D 29/0275
20130101 |
Class at
Publication: |
52/604 ; 249/160;
264/299 |
International
Class: |
E04C 2/04 20060101
E04C002/04 |
Claims
1. A wall block mold comprising first and second opposing side
forming surfaces and first and second opposing face forming
surfaces, the first and second side forming surfaces and first and
second face forming surfaces being positioned to form a perimeter
of a mold cavity in the shape of a wall block, at least one of the
face forming surfaces having a stepped surface contour which steps
outwardly from a top of the mold cavity to a bottom of the mold
cavity, the stepped surface contour defining a plurality of planar
surfaces, each planar surface having a non-linear edge, each
non-linear edge of a planar surface being joined to a non-linear
edge of an adjacent planar surface by a ledge, each planar surface
being angled outwardly from vertical in the direction of the bottom
of the mold cavity by an angle .alpha. which is greater than
0.degree..
2. The wall block mold of claim 1 further comprising a frame
including first and second opposing side walls and first and second
opposing end walls and wherein the at least one face forming
surface having a stepped surface contour comprises a face forming
liner attached to one of the side walls.
3. The wall block mold of claim 2 wherein the face forming liner
has a thickness at the top of the mold cavity which is greater than
a thickness at the bottom of the mold cavity to thereby provide the
outwardly stepped contour.
4. The wall block mold of claim 1 wherein both the first and second
face forming surfaces have a stepped surface contour.
5. The wall block mold of claim 1 wherein angle .alpha. is in the
range of about 1.degree. to 10.degree..
6. The wall block mold of claim 1 wherein each ledge comprises a
ledge surface that is angled downwardly from horizontal in a
direction away from the mold cavity at an angle .beta. which is
greater than 0.degree..
7. The wall block mold of claim 6 wherein angle .beta. is in the
range of about 1.degree. to 10.degree..
8. The wall block mold of claim 7 wherein angle .beta. is about
4.degree..
9. The wall block mold of claim 1 wherein the plurality of planar
surfaces are substantially parallel.
10. The wall block mold of claim 1 further comprising a plate which
forms the bottom surface of the mold cavity.
11. A method of making a wall block comprising: providing a mold
having first and second opposing side forming surfaces and first
and second opposing face forming surfaces, the first and second
side forming surfaces and first and second face forming surfaces
being positioned to form a perimeter of a mold cavity in the shape
of a wall block, at least one of the face forming surfaces having a
stepped surface contour which steps outwardly from a top of the
mold cavity to a bottom of the mold cavity, the stepped surface
contour defining a plurality of planar surfaces, each planar
surface having a non-linear edge, each non-linear edge of a planar
surface being joined to a non-linear edge of an adjacent planar
surface by a ledge, each planar surface being angled outwardly from
vertical in the direction of the bottom of the mold cavity by an
angle .alpha. which is greater than 0.degree., the mold further
having a plate forming a bottom of the mold cavity; filling the
mold cavity with a moldable material; and removing the moldable
material from the bottom of the mold cavity with the moldable
material resting on the plate.
12. The method of claim 11 wherein the mold has a frame including
first and second opposing side walls and first and second opposing
end walls and wherein the at least one face forming surface having
a stepped surface contour comprises a face forming liner attached
to one of the side walls.
13. The method of claim 12 wherein the face forming liner has a
thickness at the top of the mold cavity which is greater than a
thickness at the bottom of the mold cavity to thereby provide the
outwardly stepped contour.
14. The method of claim 11 wherein both the first and second face
forming surfaces have a stepped surface contour.
15. The method of claim 11 wherein angle .alpha. is in the range of
about 1.degree. to 10.degree..
16. The method of claim 11 wherein each ledge comprises a ledge
surface that is angled downwardly from horizontal in a direction
away from the mold cavity at an angle .beta. which is greater than
0.degree..
17. The method of claim 16 wherein angle .beta. is in the range of
about 1.degree. to 10.degree..
18. The method of claim 17 wherein angle .beta. is about
4.degree..
19. The method of claim 11 wherein the plurality of planar surfaces
are substantially parallel.
20. A wall block comprising first and second opposing side
surfaces, first and second opposing face surfaces, and opposing
upper and lower surfaces, the side surfaces, face surfaces and
upper and lower surfaces together defining a block body, at least
one of the face surfaces having a stepped surface contour which
steps inwardly from one of the upper surface and lower surface of
the block to the other of the upper surface and lower surface of
the block, the stepped surface contour defining a plurality of
planar surfaces, each planar surface having a non-linear edge, each
non-linear edge of a planar surface being joined to a non-linear
edge of an adjacent planar surface by a ledge, each planar surface
being angled inwardly from vertical by an angle .alpha. which is
greater than 0.degree..
21. The wall block of claim 20 wherein the at least one face
surface having a stepped surface contour steps inwardly from the
upper surface of the block to the lower surface of the block.
22. The wall block of claim 20 wherein both the first and second
face surfaces have a stepped surface contour.
23. The wall block of claim 22 wherein the first and second face
surfaces are stepped inwardly from the upper surface of the block
to the lower surface of the block.
24. The wall block of claim 20 wherein angle .alpha. is in the
range of about 1.degree. to 10.degree..
25. The wall block of claim 20 wherein each ledge comprises a ledge
surface that is angled downwardly from horizontal at an angle
.beta. which is greater than 0.degree..
26. The wall block of claim 25 wherein angle .beta. is in the range
of about 1.degree. to 10.degree..
27. The wall block of claim 26 wherein angle .beta. is about
4.degree..
28. The wall block of claim 20 wherein the plurality of planar
surfaces are substantially parallel.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/944,177, filed Jun. 15, 2007, entitled "Method
of Manufacturing a Block", the contents of which are hereby
incorporated by reference herein.
FIELD OF THE INVENTION
[0002] This invention relates generally to a method of
manufacturing a block, the block and walls constructed from such
blocks. In particular, this invention relates to a block
manufactured with a one or more faces that have a plurality of
irregularly contoured strata and ledges on a plurality of
planes.
BACKGROUND OF THE INVENTION
[0003] In the manufacture of retaining wall blocks and other kinds
of blocks made from concrete, it is common to use a mold that forms
a block module which is then split to form two or more blocks. When
a block module is split, the split surface has an irregular
appearance, which is desirable if the desired look is one of
natural stone. A split block appearance has a desirable appearance
for many applications, such as retaining walls and landscaping
products.
[0004] A typical retaining wall block has substantially parallel
top and bottom surfaces and substantially parallel front and back
surfaces. Side surfaces may have various angles or contours
relative to the front and back surfaces, or could also be
substantially parallel. In forming block modules of such blocks, it
is often standard practice to split a block module on a plane
coincident with the front faces of two blocks, thus giving the
front faces of two opposing blocks an irregular (i.e., roughened)
appearance.
[0005] U.S. Pat. No. 5,827,015 describes the conventional dry cast
manufacturing process used to manufacture concrete wall blocks. In
such process, a mold box is used to form a block module or slab
that is subsequently split into two wall blocks. It is also known
to provide mold boxes which can simultaneously form multiple slabs
of identical size and shape.
[0006] Another important feature of retaining wall blocks and
blocks used in free standing walls is the appearance of the block.
The look of weathered natural stone is very appealing for walls.
There are several methods in the art to produce concrete wall
blocks having an appearance that to varying degrees mimics the look
of natural stone. One well known method is to split the block
during the manufacturing process so that the front face of the
block has a fractured concrete surface that looks like a natural
split rock. This is done by forming a slab in a mold and providing
one or more grooves in the slab to function as one or more
splitting planes. The slab is then split apart to form two or more
blocks. Another method is wherein blocks are individually formed in
a mold and the surfaces are textured by removal of the mold.
Additional machine texturing processes can then be applied. Many
manufacturers also vary the color and the texture or pattern on the
front face of the block. It might be desirable for the face of the
block to be smooth, serrated, or grooved or to have an aggregate
appearance.
[0007] Another method to create a weathered stone appearance is to
tumble the blocks together with other blocks in a large rotating
canister. The collisions of the blocks in the tumbler chips off
random pieces of the blocks, rounding the edges and creating a look
that can be quite close to the appearance of a natural stone. This
is a labor intensive undertaking that also can result in
undesirable damage to the blocks and high overall costs of
production.
[0008] Another known method of creating a block having an irregular
or textured surface is to form the block in a mold box that has
been provided with a sidewall liner shaped to impart the irregular
or textured surface on the block during the block molding process.
The block is formed in a cavity bounded by a pallet upon which the
mold box rests and the sidewalls of the mold box. After the
material which forms the block has set enough to retain its shape a
compression head having a stripper shoe positioned above the top of
the mold box is used to compress the material and urge it out
through the bottom of the mold box. The block remains on the pallet
and is moved to a curing station. Since the block material is
removed out the bottom of the mold box the side walls of the mold
box are typically angled outwardly towards the bottom of the mold
box at a slight angle which may be between about 1 to 5 degrees.
This reduces the possibility that the material will hang up in the
mold box during removal due to either vacuum or suctional forces
caused by remaining liquid in the material or undercut areas in the
side wall.
[0009] Creating a random, or ashlar, pattern in the face of a wall
is highly desirable. This gives the appearance of a mortared or
dry-stacked natural stone wall, which is a traditional and well
accepted look. Some current wall blocks are intended to create an
ashlar pattern. However, the creation of a truly random appearance
requires the production of multiple block shapes for use in a
single retaining wall. This is inefficient from a production
standpoint because this requires multiple molds and more kinds of
blocks to inventory. If only one face of the block is intended to
be the front face, then the block system will suffer a trade-off
between having enough face sizes to create a random, natural
appearance and the cost and inefficiency of using multiple molds
and creating multiple inventory items.
[0010] It would be desirable to have a method of manufacturing
blocks for a wall that provides for an attractive appearance of a
natural ledge or ashlar stone wall with a cost-effective and easy
to install construction.
[0011] It would be further desirable to provide the face of the
block with irregular contours of multiple strata and ledges on a
plurality of different planes to enhance the dimension and depth of
the block face and thus the wall constructed with such blocks.
[0012] It would be further desirable to create such blocks from a
single mold with multiple different strata and ledges patterns to
increase the variability and randomness of the block wall.
SUMMARY OF THE INVENTION
[0013] The present invention relates a method of manufacturing a
block that has a stepped-back strata and ledges imprinted on one or
more faces of the block. A mold box is provided with a block face
liner that is machine cut to create a particular strata and ledge
pattern that is widest at the top of the liner and steps back over
a plurality of planes to a narrower width at the bottom of the
liner. Masonry material is allowed to form in the mold box around
the liner to produce the strata and ledges imprint onto one or more
faces of the block. The invention also relates to the mold box and
to blocks formed in the mold box and methods of constructing walls
with the blocks. Multiple embodiments of the block face liner for
the mold box are disclosed for enabling blocks with differing
strata and ledges formed on the faces of the blocks to be formed in
a single mold box by changing the liner.
[0014] In one aspect the present invention is a wall block mold
including first and second opposing side forming surfaces and first
and second opposing face forming surfaces, the first and second
side forming surfaces and first and second face forming surfaces
being positioned to form a perimeter of a mold cavity in the shape
of a wall block. The wall block mold also includes at least one of
the face forming surfaces having a stepped surface contour which
steps outwardly from a top of the mold cavity to a bottom of the
mold cavity, the stepped surface contour defining a plurality of
planar surfaces, each planar surface having a non-linear edge, each
non-linear edge of a planar surface being joined to a non-linear
edge of an adjacent planar surface by a ledge, each planar surface
being angled outwardly from vertical in the direction of the bottom
of the mold cavity by an angle .alpha. which is greater than
0.degree..
[0015] The wall block mold may also have a frame including first
and second opposing side walls and first and second opposing end
walls and wherein the at least one face forming surface having a
stepped surface contour has a face forming liner attached to one of
the side walls. The face forming liner may have a thickness at the
top of the mold cavity which is greater than a thickness at the
bottom of the mold cavity to thereby provide the outwardly stepped
contour.
[0016] The wall block mold may further include first and second
face forming surfaces having a stepped surface contour.
Additionally, angle .alpha. of the wall block mold may be in the
range of about 1.degree. to 10.degree.. The plurality of planar
surfaces of the mold may be substantially parallel and the mold may
have a plate which forms the bottom surface of the mold cavity.
[0017] Each ledge of the wall block mold may include a ledge
surface that is angled downwardly from horizontal in a direction
away from the mold cavity at an angle .beta. which is greater than
0.degree.. Additionally, angle .beta. may be in the range of about
1.degree. to 10.degree. and may more specifically be about
4.degree..
[0018] In another aspect the present invention is a method of
making a wall block by providing a mold having first and second
opposing side forming surfaces and first and second opposing face
forming surfaces, the first and second side forming surfaces and
first and second face forming surfaces being positioned to form a
perimeter of a mold cavity in the shape of a wall block, at least
one of the face forming surfaces having a stepped surface contour
which steps outwardly from a top of the mold cavity to a bottom of
the mold cavity, the stepped surface contour defining a plurality
of planar surfaces, each planar surface having a non-linear edge,
each non-linear edge of a planar surface being joined to a
non-linear edge of an adjacent planar surface by a ledge, each
planar surface being angled outwardly from vertical in the
direction of the bottom of the mold cavity by an angle .alpha.
which is greater than 0.degree., the mold further having a plate
forming a bottom of the mold cavity. The method further including
filling the mold cavity with a moldable material and removing the
moldable material from the bottom of the mold cavity with the
moldable material resting on the plate.
[0019] The method of making a wall block where the mold may also
have a frame including first and second opposing side walls and
first and second opposing end walls and wherein the at least one
face forming surface having a stepped surface contour has a face
forming liner attached to one of the side walls. The face forming
liner may have a thickness at the top of the mold cavity which is
greater than a thickness at the bottom of the mold cavity to
thereby provide the outwardly stepped contour.
[0020] The method may further have a mold including first and
second face forming surfaces having a stepped surface contour.
Additionally, angle .alpha. of the mold may be in the range of
about 1.degree. to 10.degree.. The plurality of planar surfaces of
the mold may be substantially parallel. The method may additionally
have each ledge of the mold include a ledge surface that is angled
downwardly from horizontal in a direction away from the mold cavity
at an angle .beta. which is greater than 0.degree.. Additionally,
angle .beta. may be in the range of about 1.degree. to 10.degree.
and may more specifically be about 4.degree..
[0021] In another aspect the invention is a wall block comprising
first and second opposing side surfaces, first and second opposing
face surfaces, and opposing upper and lower surfaces, the side
surfaces, face surfaces and upper and lower surfaces together
defining a block body. The wall block having at least one of the
face surfaces having a stepped surface contour which steps inwardly
from one of the upper surface and lower surface of the block to the
other of the upper surface and lower surface of the block, the
stepped surface contour defining a plurality of planar surfaces,
each planar surface having a non-linear edge, each non-linear edge
of a planar surface being joined to a non-linear edge of an
adjacent planar surface by a ledge, each planar surface being
angled inwardly from vertical by an angle .alpha. which is greater
than 0.degree..
[0022] The wall block may include at least one face surface having
a stepped surface contour stepping inwardly from the upper surface
of the block to the lower surface of the block and additionally may
have both the first and second face surfaces having a stepped
surface contour that may step inwardly from the upper surface of
the block to the lower surface of the block. The wall block may
have the plurality of planar surfaces substantially parallel. Each
planar surface of the wall block may have angle .alpha. being in
the range of about 1.degree. to 10.degree.. Each ledge of the wall
block may have a ledge surface that is angled downwardly from
horizontal at an angle .beta. which is greater than 0.degree..
Additionally, angle .beta. may be in the range of about 1.degree.
to 10.degree. and may more specifically be about 4.degree..
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] A preferred form of the present invention will now be
described by way of example with reference to the accompanying
drawings, wherein:
[0024] FIG. 1 is a perspective view of a mold of the present
invention illustrating first, second, third and fourth mold block
cavities.
[0025] FIG. 2A is a front view of a first block face liner from the
second mold block cavity.
[0026] FIGS. 2B and 2C are cross-sectional views of the first liner
from the second cavity taken along lines 2B and 2C,
respectively.
[0027] FIG. 2D is a front view of a second block face liner from
the second mold block cavity.
[0028] FIG. 2E is a cross-sectional view of the second liner taken
along line 2E.
[0029] FIGS. 3A to 3D are front views of alternate embodiments of
block face liners of the present invention. FIG. 3E is a
cross-sectional view of the embodiment of FIG. 3D taken along line
3E. FIG. 3F is an additional front view of an alternate embodiment
of a block face liner of the present invention.
[0030] FIGS. 4A and 4B are perspective and bottom views,
respectively, of a block of the present invention.
[0031] FIGS. 5A and 5B are perspective and side views of a wall
made with the manufactured block of the present invention.
[0032] FIGS. 6A to 6H are alternating front and back views,
respectively, of first and second block faces of the wall of FIGS.
5A and 5B.
[0033] FIG. 7 is a perspective view of a wall made with the
manufactured block of the present invention.
[0034] FIGS. 8A to 8H are alternating front and back views,
respectively, of first and second block faces of the wall of FIG.
7.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] The present invention is a method of manufacturing a unique
block face appearance using block face liners in a mold box. The
block face liners in addition with other side liners and the mold
box in which the liners are inserted are used to form multiple
blocks at one time. The mold consisting of the mold box, the
liners, and a lower plate (production pallet), forms cavities for
the formation of blocks. Moldable material is placed into the mold
and consolidated by vibration for a time sufficient to allow the
material to retain the desired block shape when it is stripped or
removed from the mold. In a manufacturing process, it is desirable
to use one mold to form many blocks and for each block face to be
unique and different from each other. The block face liner forms a
block with a strata and/or ledge imprint resulting in the
appearance of natural stone such as ledgestone or ashlar stone. The
product (first set of blocks or slabs) is removed from the mold and
moved to a curing station while resting on its production pallet.
Another production pallet is positioned under the mold to receive
the moldable material which again fills the mold. In this way, many
sets of multiple blocks are formed with one mold and many lower
plates (production pallets).
[0036] This invention further comprises blocks with faces that have
been formed with the strata and ledges imprint. The invention
further includes the construction of walls with blocks made in
accordance with the invention. It is to be understood that the
strata and ledge imprint could be formed on a vast assortment of
blocks of different shapes and sizes and the block disclosed herein
is merely one example which should not be considered limiting as to
the scope of the invention. An embodiment of the block disclosed
herein is further described in commonly assigned and co-pending
U.S. patent application Ser. No. 12/124,311 entitled "Wall Block
and Wall Block System for Constructing Walls" hereby incorporated
herein by reference. These blocks are configured to be compatible
with each other in the construction of a retaining wall, a parapet
wall, and a free-standing wall. Such walls may be straight, curved,
or circular. The wall system is designed to be structurally sound
and easy to install. The wall system is especially useful in
constructing smaller walls having a height of about 3 feet or less.
Blocks may also be provided with a side connection system wherein a
side of the block is provided with a channel or slot that is
configured to engage a corresponding projection on an adjacent
block. There may be one or more channels or slots (and
corresponding projections) on the block. Typically, and preferably,
the side connection system is used on a smooth, un-textured side of
the block. The side connection system is a particular advantage in
the construction of free-standing walls. This is because the side
connection further stabilizes the wall and because the slots and
projections prevent light from showing through the wall and
together provide for a close fit of the blocks in the wall.
[0037] Referring to FIG. 1, there can be seen a multi-block mold
box 10 according to an embodiment of the present invention. Mold
box 10 generally includes opposing first and second side frame
walls 2 and 4 and opposing first and second end frame walls 6 and
8. Block mold cavities 20, 30, 40 and 50 are formed by divisional
liner 12 which spans side frame walls 2 and 4, side liners 14, 15,
16 and 17 which are positioned adjacent to end frame walls 6 and 8,
and block face liners 22a, 22b, 32a, 32b, 42a, 42b, 52a and 52b.
Core bars 60 and cores 61 (shown in dash) may also span side frame
walls 2 and 4 and are used to support core forms which create
vertical voids in the blocks produced in the mold cavities. The
space between the mold box frame walls and liners is either covered
or comprises a solid material to ensure that material entering the
mold box cannot be captured between the frames and liners. As known
in the art the side and end space liners may be separate parts
bolted or affixed to the side and/or end frame walls. Though mold
box 10 may have various dimensions, typical dimensions of this mold
box are about 18.5 inches (47.0 cm) wide (i.e., the width of both
the first and second end walls), 26.0 inches (66.0 cm) long (i.e.,
the length of both the first and second side walls), and 4 inches
(10.2 cm) thick.
[0038] Block face liners 22a, 22b, 32a, 32b, 42a, 42b, 52a, and 52b
may be machine cut to create a particular irregular contoured
strata and ledge pattern that is widest at the top of the liner
adjacent the top of the mold cavity and steps back gradually over a
plurality of planes to a narrower width at the bottom of the liner
adjacent the bottom of the mold cavity. Block face liners 22a, 32a,
42a, and 52a may have the same dimensions (heights of 4 inches and
lengths of 12 inches) and block face liners 22b, 32b, 42b and 52b
may have the same dimensions (heights of 4 inches, lengths of 9
3/16 inches) according to the present embodiment and each liner of
similar dimension may have the same or different machine cut strata
and ledges pattern. It will be appreciated that these dimensions
will be adjusted according to the size of the mold box and mold
cavities with which they are used.
[0039] FIG. 2A to 2E illustrate block face liner 32a (FIG. 2A) and
32b (FIG. 2D) of the present invention. It should be noted that the
features described with respect to face liners 32a and 32b are
equally applicable to face liners 22a, 42a, 52a and 22b, 42b, and
52b, respectively, except that the strata and ledge patterns may be
varied as desired. Block face liner 32a (which can have a height of
4 inches and a length of 12 inches) has a greater surface area than
block face liner 32b (which can have a height of 4 inches and a
length of 9 and 3/16 inches). Each stratum S or plane of the liner
is preferably positioned at a tilt of angle .alpha. which equals
about 1.degree. to 10.degree. and may more specifically be about
1.degree. from vertical and each ledge L of the stratum is
preferably positioned with an angel .beta. which equals about
1.degree. to 10.degree. and may more specifically be about
4.degree. from horizontal. These angles and the decreasing width of
the liner from top to bottom help to ensure that the liner imprints
the texture onto the block while creating enough draft in order for
the block to be properly stripped from the mold box, and thus the
liner, while retaining the imprint of the liner. However, the
degree of angles can be changed or varied as desired and the stated
angles or ranges should not be considered limiting as to the scope
of the invention. The angle should be chosen to overcome any
suctional or vacuum forces created by liquid in the mold material
which would act to resist removal of the material from the mold
cavity. Optional heat may also be added to the liners which
functions to evaporate moisture to additionally help eliminate any
vacuum or suctional forces created by the moisture in the mold
material. Cross sectional views 2B and 2C of FIGS. 2B and 2C
illustrate the variations in irregularity of the contours of the
strata S of liner 32a. The width of ledge L of each strata may be
variable as desired and may be, for example, 1/8 of an inch per
ledge. FIG. 2E illustrates cross sectional view 2E of the
embodiment FIG. 2D illustrate the variations in width and length of
the strata S and ledges L of liner 32b.
[0040] FIGS. 3A to 3F illustrate alternate embodiments of the
strata and ledges texture for a block face liner. Peak P of the
liner of FIG. 3B imparts a valley or trench onto the face of the
block which is formed from the liner. The valley/trench of the
block face is meant to give the appearance that the face of the
block is separated to appear as a left and right side, or multiple
random stones thereby adding to the randomness and variability of
the block and thus the wall formed from the block. FIG. 3D
illustrates an embodiment wherein the contours of wider second,
fourth and sixth terraces or strata 71, 73, and 75 are preceded by
substantially similar narrower first, third and fifth terraces or
strata 70, 72, and 74, respectively. FIG. 3E illustrates cross
sectional view 3E of the embodiment of FIG. 3D and illustrates
first, third and fifth ledges 80, 82 and 84 of the first, third and
fifth terraces being wider than second and fourth ledges 81 and 83
of the second and fourth terraces (there is no ledge after the
sixth terrace as the sixth terrace is at the bottom of the liner).
This embodiment may also have peaks to imprint valleys onto the
face of the block and together with the imprinted wider terraces
with similar narrower terraces gives the block face the appearance
of multiple individual stones on three separate levels of the block
face. The imprint of the wider and narrower ledges onto the block
face will also cast more shadows onto some terraces and less onto
other terraces. It should be noted that these are just a few of the
possibilities that could be formed onto the liner due to the
immense amount of variations possible for the placement of the
irregularly contoured strata and ledges. For example, the face
liners will be made to form a plurality of strata on the block
faces. The strata will comprise planes that are substantially
parallel to one another. Each stratum is bound by at least one
ledge which may be non-linear as shown in the drawings or, if
desired, may be partially or entirely linear. The blocks are formed
in the mold cavity in inverted fashion with their bottom surfaces
at the top of the mold box and their top surfaces resting on the
pallet at the bottom of the mold cavity. The strata on the blocks
are formed to step outwardly from the top of the mold cavity to the
bottom of the mold cavity so that the contour of any section along
the face of the block steps outwardly to follow the contour of the
face liner such as shown in FIGS. 2B, 2C and 2E in order to avoid
the formation of pockets, grooves, or channels which would retain
material when the block is removed from the mold box. Thus, in
their position of use the strata on the block faces step inwardly
from the top of the block to the bottom of the block as best seen
in FIG. 5B. It should be further noted that the block face liners
could be used to imprint a block face on differing styles and sizes
of blocks and therefore the dimensions of the liner could vary
greatly.
[0041] FIG. 3F illustrates an alternate embodiment for a block face
liner which shows a strata layer with a more wave-like pattern and
smoother horizontal curvilinear contour between each ledge.
[0042] As with conventional mold boxes, the mold box of the present
invention are configured to rest upon a pallet to form cavities.
Masonry material is deposited into block mold cavities 20, 30, 40
and 50 and later removed by stripper shoes on a head assembly that
contact the masonry material from above, compress it, and then push
it through the mold while the mold is held firmly in a stationary
position in the mold machine in accordance with procedures well
known to those of skill in the art. The draft created by angles
.alpha. and .beta. and the narrowing width of the block face liners
allow the masonry material to be properly stripped from the liner,
thus releasing cleanly from the liner face. Prior to the masonry
material being removed from the mold cavity heat may be introduced
to help ensure that the masonry material strips cleanly from the
mold cavity and the strata and ledge imprint on the face/faces of
the block keeps their shape and do not fragment. The masonry
material typically is a rugged, weather resistant material,
preferably (and typically) zero-slump molded concrete. Other
suitable materials include wet cast concrete, plastic, reinforced
fibers, wood, metal and stone. Vibratory action compresses the
material contained within the mold cavities. Stripper shoes which
help push the molded block out of the mold cavity do not touch the
mold liners, division plates or division plate liners. The blocks
are formed in the mold box with their bottom surfaces facing
upward, thus the block face liner which imparts the strata and
ledge imprint to the block face will be thicker towards the bottom
surface of the block in the mold cavity (i.e., the top surface when
in the mold), and then step back and narrow toward the top surface
of the block (i.e., the bottom surface when in the mold). This
step-back imprint of the strata and ledges imparted by the face
liner to the block face helps to create shadows and dimension as
light hits each plane on the face of the block when it is inverted
from how it is made in the mold and placed in a wall assembly,
giving the block a more natural and visually pleasing appearance.
It should be noted that the block could also be used bottom side up
as desired, but in this case the sunlight will not create shadows
from the textured imprint.
[0043] FIGS. 4A and 4B illustrate a first embodiment of a first
block 100 of this invention. Block 100 could be produced from any
one or all of cavities 20, 30, 40 and 50 of mold box 10. Block 100
comprises lower surface 104 opposed and substantially parallel to
upper surface 102, and opposing and substantially parallel first
and second (also referred to as front and back) faces 106 and 108,
respectively. The upper and lower surfaces are separated by the
thickness of the block. For the purposes of this description, first
face 106 is shown facing the viewer in FIG. 4A, however, it is to
be understood that the first faces of some blocks and second faces
of other blocks are in some situations exposed on the same side
when the blocks are used in a wall. Thus, the textured pattern of
strata and ledges is formed in both faces as described above. The
block also comprises opposing and converging side surfaces 110 and
112 (i.e., imaginary lines coincident with side surfaces 110 and
112 will eventually converge at some distance away from the second
face or back of block 100) and are separated by the width of the
block. The converging side surfaces result in first face 106 having
a larger surface area than second face 108. First face 106 and
second face 108 have been molded with the strata and ledge imprint
of the present invention. It should be noted that just one of the
sides may have been imprinted if so desired. Side surfaces 110 and
112 have curvilinear recesses 114. Block 100 is preferably used
with upper surface 102 facing up when constructing a wall to
enhance the visual appearance of the wall and to allow the
plurality of stepped-back planes to cast shadow and add dimension
to the block and wall as shown in FIG. 5B. It should be noted
however that lower surface 104 could also be placed facing up if so
desired. Block 100 is provided with core 116 that extends through
the thickness of the block. Preferably core 116 is circular.
[0044] Block 100 can be sized to desired dimensions. For example,
the thickness of the block can be 4 inches (10.2 cm), the width of
the block can be 12 inches (30.5 cm) along a first face 106a and
93/8 inches (23.8 cm) along the second face 108a and the depth of
the block between the first and second faces can be 73/4 inches
(19.7 cm).
[0045] FIGS. 5A and 5B illustrate a wall made with multiple wall
blocks having multiple different faces of strata and ledges
imprints. The multiple different strata and ledge imprints give the
wall a more random and natural appearance enhancing the wall's
visual appearance. Generally, when constructing a wall, a trench is
excavated to a pre-selected depth and lined with a level base of
granular material such as crushed stone. A base layer is then
placed and leveled onto the crushed stone. The blocks are placed
side to side with a first face facing outward and the bottom
surface facing downward. Optionally a "D" can be molded onto the
bottom surface of the block (top surface when in the mold) to
facilitate orientation (the "D" standing for down). A straight wall
is produced by alternating the placement of the first and second
faces of blocks relative to each adjacent block (i.e. first face
106 of a block is placed projecting outward and then the second
face 108 of an adjacent block is placed projecting outward). The
adjacent block is placed and the projection and slot of the side of
one block fits securely into the slot and projection of the
adjacent block. This interlocks adjacent blocks in a course giving
the wall more stability without the use of pins and pin receiving
apertures typically found in prior art block systems. Once the base
layer is laid, subsequent layers are placed one on top of the next
until the desired height is reached. Once the desired height is
reached a capping layer may be added. Typically, the placement of
blocks are vertically offset in adjacent courses in a running bond
pattern. Curvilinear recesses (i.e. 114) of the side surfaces (i.e.
110 and 112) form substantially circular cavities when laid side to
side and are substantially similar in size and shape to the core
(i.e. 116). The cores and cavities overlap one another in adjacent
courses producing vertical columnar cavities inside the wall
structure. The circular shape of the cores and cavities helps to
maximize the alignment and functional volume of the vertical
cavity. These columnar cavities may be filled with a stabilizing
material such as sand, gravel, sheer resistant fill (i.e. crushed
stone), concrete, cement or the like, to give the wall added
stability. The interlocking projections and slots along with the
stabilizing material added to the vertical columnar cavities
stabilize the wall making it structurally sound without the use of
traditional stabilizing systems such as pins and the like.
Optionally, construction adhesive may be used to lack blocks and/or
courses together with or without the use of stabilizing
materials.
[0046] FIGS. 6A to 6H illustrates the wall of FIGS. 5A and 5B made
with multiple wall blocks having multiple embodiments of the strata
and ledges texture for the block faces. FIGS. 6A, 6C, 6E and 6G
illustrate first or front faces of blocks used in the construction
of the wall while FIGS. 6B, 6D, 6F and 6H are the second or back
faces of the blocks with first faces of FIGS. 6A, 6C, 6E and 6G,
respectively. It should be noted that the first and second faces
could have any combination of surface textures imprinted on them
and could even have the same texture. It should also be noted that
other types of wall blocks could be imprinted with the strata and
ledge texture and that the block shown in the drawings is just an
example.
[0047] FIG. 7 illustrates a wall made with multiple wall blocks
having multiple different faces of strata and ledges imprints. The
multiple different strata and ledge imprints shows a strata layer
with a more wave-like pattern and smoother horizontal curvilinear
contour between each ledge and gives the wall a more random and
natural appearance.
[0048] FIGS. 8A to 8H illustrates the wall of FIG. 7 made with
multiple wall blocks having multiple embodiments of the strata and
ledges texture for the block faces. FIGS. 8A, 8C, 8E and 8G
illustrate first faces of blocks used in the construction of the
wall while FIGS. 8B, 8D, 8F and 8H are second faces of the blocks
with first faces of FIGS. 8A, 8C, 8E and 8G, respectively. It
should be noted that the first and second faces could have any
combination of surface textures imprinted on them and could even
have the same texture. It should also be noted that other types of
wall blocks could be imprinted with the strata and ledge texture
and that the block shown in the drawings is just an example.
[0049] Although particular embodiments have been disclosed herein
in detail, this has been done for purposes of illustration only,
and is not intended to be limiting with respect to the scope of the
claims. In particular, it is contemplated that various
substitutions, alterations, and modifications may be made to the
invention without departing from the spirit and scope of the
invention as defined by the claims. For instance, the choice of
materials or variations in the shape or angles at which some of the
surfaces intersect are believed to be a matter of routine for a
person of ordinary skill in the art with knowledge of the
embodiments disclosed herein.
* * * * *