Patent Application
20050016123
1. Field of the Invention
The present invention relates generally to apparatus and methods for manufacturing structural units, such as concrete blocks, brick, clay-based material, pavers, segmental retaining walls (SRWs), etc., from a mold and, in particular, to an insert apparatus for use in connection with a mold for manufacturing a concrete unit, a method of manufacturing a concrete unit having a design or indicia applied on a side or sides of the unit, a method of installing a plurality of concrete units as a wall surface and a method of retrofitting an existing mold for manufacturing a concrete unit having a design or indicia applied on a side thereof.
2. Description of Related Art
In the field of manufacturing concrete units, such as concrete, concrete blocks, pavers, bricks, SRWs and the like, a mold is required. In operation, a conveyor or similar transport mechanism moves a pallet or plate underneath the mold, which typically includes an open top, open bottom and multiple inner cavities for forming the concrete unit. After the pallet or plate has moved into engagement with the underside of the mold, a fill drawer moves over the open top of the mold and places material, such as concrete or cement, into the inner cavity portion of the mold. Next, a machine head or plunger compresses the material, thereby providing additional compaction of the concrete material in the mold. Typically, the mold is vibrated while the concrete material is being placed or injected therein to provide better settling and uniformity.
After the concrete material is molded or shaped within the inner cavity of the mold, the pallet or plate moves down in a vertical manner away from the bottom of the mold and the compacted, consolidated and condensed concrete units also move down with the pallet. Typically, the concrete units are further cured, such as by natural curing, or by some other catalytic means. In this manner, a concrete unit is manufactured.
Concrete units, such as blocks, are now being used extensively in both consumer and construction situations. For example, a consumer may now wish to build his or her own retaining wall or decorative wall on their property. Accordingly, a need has arisen for more functional, decorative and/or aesthetically pleasing concrete units. Therefore, in order to manufacture such specialized units, typically the mold must be modified to apply a design surface. There are different processes for accomplishing a decorative or roughened surface, with the two typical processes being either roughening the surface as the unit is dropped down through the mold or mechanically impressing a design or indicia using complicated mechanical devices or a labor-intensive single mold apparatus.
One drawback to applying a design or other indicia on a concrete unit is the limitation of how a concrete unit is manufactured by the mold. As discussed above, the bottom or plate moves to bound the mold and allow concrete material to be placed therein, and when this material is consolidated/compacted/condensed (CCC), the pallet or plate moves away from the bottom of the mold in a vertical direction. Therefore, any design that is placed upon a vertical surface of the concrete unit would be removed or otherwise distorted as the CCC concrete unit drops and slides down through the mold via the pallet. However, this does not pose an insurmountable problem when merely producing concrete units with a roughened surface. Since the design is not specific and only a roughened surface is desired, systems and processes have been developed for applying such a roughened surface to a unit. For example, see U.S. Pat. No. 6,464,199 to Johnson; U.S. Pat. No. 6,209,848 to Bolles et al.; U.S. Pat. No. 6,138,983 to Sievert; U.S. Pat. No. 6,113,379 to LaCroix et al.; U.S. Pat. No. 5,217,630 to Sayles; and U.S. Pat. No. 5,879,603 to Sievert. See also Patent Application Publication No. U.S. 2001/0007380 to LaCroix et al. However, such processes and molds are deficient in that only a roughened or textured surface can be applied to the vertical face of the unit. Therefore, such systems and processes are not capable of producing a specified design or indicia, which would not be removed or distorted as the CCC concrete unit is discharged from the mold.
Other processes have been developed for placing decorative surfaces, designs and indicia on a vertical face of a concrete unit. For example, see U.S. Pat. No. 5,817,249 to Forlini; U.S. Pat. No. 2,532,049 to Wittke; U.S. Pat. No. 1,693,693 to Dexter; and U.S. Pat. No. 1,635,093 to McPherson et al. However, these molds and processes are quite complicated. The mold must be specifically designed to create the design or indicia and typically a wall of the mold must be pressed in toward the concrete material and then removed prior to dropping the unit from the mold. In addition, such intricate molds and machines are expensive and labor intensive, since multiple parts and walls and other mechanisms must be utilized to apply the indicia, remove the design portions and allow the block to be removed from the mold. Further, such molds and processes may not be well suited for the mass production of concrete units.
It is, therefore, an object of the present invention to provide an insert apparatus, a method of manufacturing and a method of retrofitting a mold for manufacturing a structural unit that overcomes the deficiencies of the prior art. It is another object of the present invention to provide an insert apparatus and methods of manufacturing a structural unit having a design, indicia, projection or recess on one or more vertical surfaces of the unit. It is yet another object of the present invention to provide an insert apparatus and methods of manufacturing a structural unit that changes the general dimensions of the unit. It is a still further object of the present invention to provide an insert apparatus for use in connection with a mold for manufacturing a structural unit that is simple in its use and does not remove or otherwise distort the applied design when the unit is removed from the mold. It is another object of the present invention to provide a method of manufacturing a structural unit having a design or indicia impressed or recessed upon a vertical side or sides of the unit that is more efficient and capable of mass manufacturing such units. It is a still further object of the present invention to provide a method of retrofitting an existing mold, such that a structural unit can be produced having a design, indicia, projection or recess thereon.
The present invention is directed to an insert apparatus for a mold for manufacturing at least one structural unit. The insert apparatus includes a carrier configured to operatively engage the mold. The insert apparatus also includes a face having design portions and in operative communication with the carrier portion. The design portions extend into or out of an inner cavity of the mold.
The present invention is also directed to a method of manufacturing a structural unit having a design or indicia applied on at least one side of the unit. The method includes the steps of: (a) engaging a carrier within a mold, where the carrier is in operative communication with a face having design portions extending into or out of an inner cavity in a mold; (b) placing a material into the inner cavity of the mold, such that one or more sides of the inner cavity comprise the face portion; (c) at least one of consolidating, compacting and condensing the material, thereby forming the structural unit; and (d) removing the structural unit from the mold.
The present invention is also directed to installing a plurality of structural units as a wall. This method includes the steps of: providing multiple structural units, where some or all of these units include a design portion extending from and/or recessed within a face surface of the structural unit; successively applying mortar to a surface of the structural unit and positioning a successive structural unit on the mortared surface, thereby forming the wall with a wall surface having a desired master design thereon; and applying additional mortar to at least one mortar joint between at least two structural units, the additional mortar effectively joining the design portions between the at least two structural units, thereby providing a more complete desired master design on the wall surface.
The present invention is further directed to a method of retrofitting an existing mold for manufacturing a structural unit having a design or indicia applied on at least one side of the unit. The mold includes an inner cavity with one or more sides comprising the plate element removably attached to the side. The method includes the steps of: (a) detaching and removing the plate element from the side of the inner cavity of the mold; (b) providing an insert apparatus including a carrier in operative communication with a face having design portions; and (c) engaging the carrier in place of the removed plate element, wherein the design portions of the face portion extend into or out of the inner cavity of the mold.
The present invention is also directed to an improvement for use in connection with a mold for manufacturing a structural unit having a design applied on at least one side of the unit. The improvement comprises an insert. This insert is configured to operatively engage a portion of the mold. The insert comprises a carrier having a face portion with at least one design portion extending into or out of the inner cavity of the mold.
The present invention is also directed to an insert for a mold for manufacturing at least one structural unit. The insert includes a carrier configured to operatively engage a portion of the mold. In addition, the carrier includes a face portion with at least one design portion extending into or out of the inner cavity of the mold.
The present invention, both as to its construction and its method of operation, together with the additional objects and advantages thereof, will best be understood from the following description of exemplary embodiments when read in connection with the accompanying drawings.
For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral” and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.
The present invention is directed to an insert apparatus 10, as shown in various embodiments in
In one preferred and non-limiting embodiment, the insert apparatus 10 is for use in connection with the mold 110 for manufacturing one or more structural units 100. In particular, the insert apparatus 10 includes a carrier 12 that is adapted to operatively engage a portion or part of the mold 110. Further, the insert apparatus 10 includes a face 14, and this face 14 includes one or more design portions 16 thereon. In addition, the face 14 is in operative communication or engagement with the carrier 12. The design portions 16 extend into or out of the inner cavity 112 of the mold 110.
As best seen in
In another embodiment, the carrier 12 and the face 14 may be constructed or manufactured as an integral piece. This may be particularly useful in an application where different patterns are not required, and the same insert apparatus 10 can be used in connection with the same mold 110 throughout the process. In this embodiment, the carrier 12, face 14 and design portions 16 are an integral unit.
In a further embodiment, and as illustrated in
As discussed above, the face 14 may be removably attachable to the carrier 12. Therefore, a removable attaching means 30 facilitates the releasably attachable functionality of either one or both of the face surfaces 14 with respect to the carrier 12. In particular, the face 14 would be removably attachable to either the first side surface 22 and/or the second side surface 24. Specifically, it is the removable attaching means 30 that allows the face 14 to engage the carrier 12 in a removable and non-permanent manner. Any removable attaching means 30 is envisioned, such as an attachment device, an adhesive compound, interacting magnetic elements, a flange and groove arrangement, a male/female plug arrangement, an elongated member in operative communication with the carrier 12 and a face 14, a clamp, etc.
In one preferred and non-limiting embodiment, one or more pins 32 could be provided as the removable attaching means 30. These pins 32 could be insertable through corresponding pin orifices 34 on the carrier 12, and further and aligned pin orifices 36 on the face 14. As shown in
A mold 110 according to the prior art is illustrated in
It should be noted that this arrangement is for constructing two structural units 100, and any number of side plate elements 122 and end plate elements 124, when used in connection with variously sized and shaped molds 110, will provide for the manufacture of one or multiple variously sized and shaped structural units 100. In the present embodiment, the end plate elements 124 are secured to the first end wall 118 and the second end wall 120 in such a way that each end plate element 124 includes a first end that abuts a side plate element 122 and a free end, which forms a groove 126. In addition, the mold 110 may include one or more structural unit cavity forms 128, which assists in forming cavities in the structural unit 100 after the material is injected into the inner cavity 112 of the mold 110.
Returning to the insert apparatus 10, the carrier 12 may include a projection 38 or a groove 40 on a surface of the carrier 12. This projection 38 and/or groove 40 is adapted to mate with a complimentary projection 42 or groove 44 located on a surface within the inner cavity 112 of the mold 110. For example, as seen in
In one preferred and non-limiting embodiment, and as illustrated in
The carrier 12 may be manufactured from a variety of materials, for example, the carrier 12 may be manufactured from a thermoplastic material, a synthetic material, a plastic, a polymer, wood, a rigid material, etc. Similarly, the face 14 may be manufactured from a variety of materials. For example, the face may be manufactured from a thermoplastic material, a synthetic material, a plastic, a polymer, wood, a rigid material, a flexible material, a foam, a closed-cell foam, etc. In one preferred and non-limiting embodiment, the face 14 is manufactured from a closed-cell polymeric material.
It is envisioned that a different design portion 16 is disposed upon the face surface 46 of a plurality of faces 14, and each different design portion 16, when produced in a line, create a desired master design 48. For example, see
In operation, and according to the present method of manufacturing a structural unit 100, the carrier 12 is engaged within the mold 110. Further, the carrier 12 already includes or is in operative engagement with one or more faces 14. As seen in
It is envisioned that, according to the prior art and typical processes, a block machine (not shown) can be used to compact and assist in forming a structural unit 100 after the concrete or similar material has been placed into the inner cavity 112 of the mold 110. Similarly, a vibration apparatus may also be used to help in settling, consolidating, compacting and condensing the material, as is known in the art. After the insert apparatus 10 is placed in the mold 110, the process according to the prior art proceeds accordingly. After the concrete unit is consolidated, compacted and condensed, the pallet 140 is vertically dropped down, carrying with it the newly-formed structural unit 100, having a design portion 104 disposed thereon. It is envisioned, at this point, that the structural unit 100 will be dropped down together with the insert apparatus 10, which is still adhered to or attached to the structural unit 100 or units. It is envisioned that the carrier 12 may be removed mechanically (or by hand) from the insert apparatus 10 at this point in the process or at some later point. Further, the face 14 may be disengaged from the carrier 12 and a new face 14 replaced thereon. In addition, the structural unit 100 may be further cured before subsequent use and the face 14 may be removed at this point.
It is often necessary for the insert apparatus 10 to be removably engaged with the mold 110 for effective creation of the structural unit 100. Therefore, it is also envisioned that one or multiple modified end plates 130, as discussed above, can be introduced at any one or more locations within the mold 110. Due to the shape of the projection 42 on the modified end plate 130, and the complimentary groove 40 on the carrier 12 (see
In another aspect of the present invention, a presently existing mold 110 may also be retrofitted for forming the desired structural units 100. For example, the insert apparatus 10, the carrier 12 and/or the face 14 can take the place of any one or more of the side plate elements 122 and the end plate elements 124. Further, any vertical surface that is removable and replaceable, may be replaced with an appropriately sized and shaped insert apparatus 10, carrier 12 and/or face 14 for forming a design or indicia on any one or more of the vertical faces of the structural unit 100. Due to the easy engagement and appropriate size of the insert apparatus 10, the present invention is particularly adaptable to suit any of a variety of design considerations and options. This provides the user with the maximum amount of flexibility in choosing the designs to satisfy a consumer's needs. Therefore, the present invention is useful in both mass production of structural units 100, as well as special order units.
As discussed above, the insert apparatus 10 may be formed as an integral insert including the carrier 12 and the face 14. In this preferred and non-limiting embodiment, the carrier 12 would engage at least a portion of the mold 110, and the carrier 12 would include the face 14 as a face portion or integral portion of the carrier 12. As discussed above, the face 14 would include one or more design portions 16 extending into or out of the inner cavity 112 of the mold 110. Accordingly, this integrated carrier 12 and face 14 (with design portions 16) could be engaged with and fit into a pre-existing mold 110 for use in constructing the structural unit 100, as discussed in detail above.
Turning now to the method of installing a plurality of structural units 100, a step in the method and various end results are illustrated in
A different design portion 104 may be disposed upon the face surface of the structural units 100, and each different design portion 104, when arranged and aligned to a predetermined position, create the desired master design 48. In this manner, a projecting or relief design may be formed on the wall surface 103 of the wall 102. The wall 102 may be a retaining wall, a structural wall, a room wall, an architectural wall, an aesthetic wall, etc.
In this manner, an insert apparatus 10 is provided for forming a design or indicia upon one or more vertical faces of the structural unit 100, typically a concrete or cement unit. In addition, the present invention provides a method of manufacturing a structural unit 100 having a design portion 104 on the structural unit 100, and this process is adaptable, flexible and more simple in operation than the prior art processes. Still further, the present invention provides a method of retrofitting an existing mold 110 for manufacturing such structural units 100. During the typical bottom loading and unloading process, the design or indicia formed on the structural unit 100 would not be removed or distorted in any way, since the insert apparatus 10 is ejected along with the structure 100. Further, the insert apparatus 10 does not use complicated machinery and extensive labor to successfully employ. Also provided is a method of installing a plurality of structural units 100 as a wall 102 having a wall surface 103. When built in accordance with this method, a desired master design 48 is displayed, and this method provides new and unexpected results in the fields of masonry and design architecture.
This invention has been described with reference to the preferred embodiments. Obvious modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations.
This application claims the benefit of U.S. Patent Application Ser. No. 60/489,987, filed Jul. 25, 2003, which is herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 60489987 | Jul 2003 | US |
