The present invention is relates to the manufacture of masonry blocks. More specifically, the present invention relates to an apparatus used in conjunction with a masonry block mold, and which imparts a texture to the block as it is removed from the mold.
Manufactured masonry blocks have been used for many years to construct a wide variety of structures. One reason that they have enjoyed their popularity is that they may be formed into many shapes and may include different surface finishes. For example, a masonry block may be in the shape of a “cinder block” and have substantially smooth front and rear surfaces. Or, a masonry block may be in the shape of a retaining wall block and have split-face or roughened surface. Typically, the rustic look is achieved by constructing a mold so that two blocks are formed together in a face-to-face relation, removing the unitary block from the mold, and then splitting the block apart at a common plane to form two blocks, with each block having a roughened surface. This procedure, however, requires additional time to perform, specialized equipment, and trained operators, and this all adds to the cost of manufacture. Various attempts have been made to simplify the process of manufacturing a masonry block having a roughened surface.
One attempt can be found in U.S. Pat. No. 3,904,229 to Hutton. In this disclosure, a roughened surface is formed on a block by providing a lip that protrudes inwardly from the bottom of a wall in a mold. As a block is stripped from its mold, the lip scrapes or otherwise tears the surface to form a roughened surface. This device has its disadvantages in that block material tends to collect above the lip as a block is stripped from a mold. This reduces the effectiveness of the lip and requires that the mold be periodically cleaned for optimum operation. Moreover, this device is limited to the type of texturing that may be imparted to the surface of a block.
Other attempts, such as U.S. Pat. Nos. 5,078,940 and 5,217,630 (both to Sayles) are similar to the patent of Hutton in that block material remains within the mold as a block is stripped therefrom. Sayles differs from Hutton, however, in that this retention of material is intentional. In order to retain material in his mold, Sayles provides one of the walls of his mold with a relatively elaborate series of projections and a reinforcing mesh. A roughened surface is formed as this retained block material is sheared from a block as it is stripped from a mold. This attempt has its disadvantages in that the block material retained within the mold must be periodically replaced in order to be effective.
Still other attempts, such as U.S. Pat. Nos. 5,879,603 and 6,138,983 (both to Sievert) form a roughened surface by providing inwardly protruding upper and lower lips at the top and bottom, respectively, of a wall of a mold. These lips retain a portion of block material therebetween and facilitate a shearing action as a block is stripped from a mold. The lower lip also is used to a lesser extent to further work the surface of a block as it is being stripped from the mold. This attempt has its disadvantages in that, like the afore-mentioned patents of Hutton and Sayles, a portion of block material is still retained by the mold, and processing of this material requires additional time and steps.
The above-mentioned patents of Hutton, Sayles, and Sievert also share the same disadvantage in that they are more or less designed to be part of the mold itself. That is, they are limited to use an as a wall of a mold. There is no provision for use with existing molds, as for example, a divider plate. They also share the same disadvantage in that the surface areas that mechanically work a surface of a block as it is stripped from a mold are small. Thus, the degree to which a surface texture may be formed by mechanically working, is limited.
In other attempts, such as U.S. Pat. Nos. 6,113,379 and 6,224,815 B1 (both to LaCroix et al.) roughened surfaces are simultaneously formed on two blocks by providing a mold with an expanded-metal dividing grate. The grate operates similarly to the above-mentioned patents of Sievert in that a roughened surface is formed primarily by shearing and to a lesser extent, mechanical working. This attempt also has its disadvantages. Its use and placement is limited to bisecting an existing mold. It cannot be used as a wall of a mold. It is structurally weak and subject to wear and tear. Also, it is limited to use with planar surfaces.
The above-mentioned patents of Hutton, Sayles, Sievert, and LaCroix also share the same disadvantage in that their block texturing molds retain a significant amount of waste material on their texturing devices, and this material eventually falls from the texturing devices onto the pallets, machinery, and newly formed blocks therebelow. This waste material not only interferes with normal operation of the machinery, but also creates unsafe working conditions, and may even ruin the newly created, but uncured blocks. Therefore, the block forming machinery must be periodically stopped and cleaned, and the blocks must be checked for waste material before they are cured.
There exists a need for a block texturing apparatus that is able to create a variety of different surface textures. There is also a need for a block texturing apparatus that generates a minimum amount of block material waste, and is self-cleaning. There is also a need for a block texturing apparatus that may be easily incorporated as a wall of a mold or as an internal divider plate within a mold.
The present invention provides a block texturing apparatus and a method for use in producing a block with a textured surface. The block texturing apparatus comprises a body having front surface, a rear surface, a top surface, a bottom surface, and opposing side surfaces. The front surface is provided with a block modifying section that is configured and arranged to form a textured surface on a block. This is accomplished in two ways. First, a textured surface is imparted to a block mixture by the block modifying section as a block is formed in a block mold. And second, the textured surface is manipulated by the block modifying section as the newly formed block is removed from the mold. In the context of this application, the term “front surface” is understood to mean the side of the block texturing apparatus that faces the interior of a mold cavity and which contacts block material (or mixture) in a mold.
The block modifying section may vary in size from being substantially coextensive with the front surface, to occupying a percentage of the front surface, for example around twenty percent. The block modifying section may be provided with a variety of profiles that produce different surface textures in a block surface. For instance, the block modifying section may comprise a plurality of parallel channels that are oriented so that they are angled with respect to the direction of removal of a block from a mold. This allows block material within the channels to be worked and redistributed over the surface of a block in churning and repacking motions.
The channels may also be varied cross-sectionally along their length, as well as with respect to each other. Thus, one channel may have a predetermined cross-sectional area and the next channel may have a predetermined cross-sectional area that is smaller or larger than the predetermined cross-sectional area of the first channel. The channels may also vary in depth along their length. They may also be provided with constrictions or shelves (at the bottom end of the block texturing apparatus) to produce, eliminate, or accentuate different textures. Preferably, the channels are v-shaped. However, it is understood that other configurations are possible, for example, a u-shape, a squared notch shape, or a hemispherical shape. It is also understood, that the channels need not all have the same general cross-sectional profile. Thus one channel may be v-shaped and the next channel may be u-shaped, and the next channel may be yet another shape.
Alternatively, it is envisioned that the block modifying section comprise a series of indentations and/or protrusions that churn, redistribute, and repack block material. Further, it is also envisioned that the indentations and/or protrusions may be similar or different in shape, and distributed in ordered or random patterns.
The block texturing apparatus is configured and arranged for use in conjunction with existing block molds and mold machinery. More specifically, the block texturing apparatus may be used in lieu of a mold wall to form a mold enclosure, used in conjunction with existing mold walls, or as in an insert adjacent an existing wall. When used in conjunction in lieu of existing mold walls, the block texturing apparatus is substantially the same size as a mold wall it replaces. However, it will be appreciated that this need not be the case. For example, the block texturing apparatus may have larger extents than the other walls of the mold. For example, the top and bottom surfaces of the block texturing apparatus may extend beyond the upper and lower edges of the mold. This would also produce different textures to a block surface.
When the block texturing apparatus is used with used in conjunction with existing mold walls, it may function as a divider plate or an insert. In this regard, the block texturing apparatus would serve as a common wall between adjacent molds. The block texturing apparatus may be used to bisect a mold, or it may be used to form asymmetric blocks, if desired. Additionally, more than one block texturing apparatus may be used with an existing mold. Thus, for example, a mold may be configured to manufacture a block having textured, faceted front surfaces, or a mold may be configured to manufacture a block having textured front and rear surfaces.
In a variation of the above-mentioned use, a block texturing apparatus may be placed next to an existing wall of a mold. This could be done to accomplish two things. First, to impart a texture to a surface of a block, and second, to change the dimensions of the block mold.
The block modifying section may be formed into different shapes, depending upon the particular shapes of the block molds that are used. For example, the block modifying section may be substantially planar or curvilinear. Alternatively, the block modifying section may be a combination of planar and curvilinear surfaces.
An object of the present invention is to provide a block texturing apparatus that manipulates surfaces of masonry blocks as they are removed from block molds.
Another object of the invention is to simplify the process of forming masonry blocks with textured surfaces as part of the molding process.
A feature of the present invention is that the block texturing apparatus may form part a mold enclosure, or may be used in conjunction with an existing mold enclosure.
Another feature of the invention is that the block texturing apparatus manipulates a surface of a masonry block as it is being removed from a mold.
Yet another feature of the invention is that the block texturing apparatus includes a block modifying section that that is self-cleaning.
An advantage of the present invention is to provide a block texturing apparatus that may be used in conjunction with existing block making equipment.
Yet another advantage is that the amount of waste material created during the texturing process is minimized.
These and other objectives, features and advantages of the invention will appear more fully from the following description, made in conjunction with the accompanying drawings wherein like reference characters refer to the same or similar parts throughout the several views. And, although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention, which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
a, 7b and 7c depict steps in the process by which a block is formed with a textured surface;
a, 8b, 8c, and 8d depict alternative embodiments of the apparatus of
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The block modifying section 40 itself encompasses an area characterized by having discontinuities. As depicted, the discontinuities of the block modifying section 40 are a plurality of recesses that, together, form an erose or jagged surface. Preferably, the recesses comprise channels 42 that are oriented at a predetermined angle 58 with respect to the direction of removal 60 of a block from a mold. This predetermined angle 58 may range from around zero to forty-five degrees, but the preferred range is around five to twenty-five degrees.
As will be appreciated, different predetermined angles 58 will produce different surface textures. For example, if the predetermined angle is zero, the resulting surface textures can approximate what is known in the trade as a “stri-face.” If the predetermined angle is around forty-five degrees, the resulting surface textures can approximate what it known as a rustic or weathered look. Yet other surface textures are possible with intermediate, predetermined angles.
As mentioned above, the block modifying section 40 occupies substantially the front surface 22 of the body 20, and the channels 42, as depicted, are substantially parallel and continuous in their extent across the front surface 22 of the body 20. However, this need not always be the case. It is envisioned that the channels could be skewed with respect to each other so that they converge and/or diverge. It is also envisioned that the channels vary in width along their longitudinal extents. That is, they may be flared or undulating. Moreover, the channels could be segmented into smaller lengths or links. As mentioned above, the cross-sectional profiles of the channels are 42 substantially v-shaped. This profile is preferred because it facilitates cleaning and makes the block modifying section easier to fabricate. It should be understood, however, that other cross-sectional configurations are possible, for example, a u-shape, or a squared slot.
Referring now to
To reiterate, the channels 42 need not all have the same cross-sectional profile, and some channels, for example, may be deeper and wider than other channels. For purposes of illustration, however, only one channel 50 in the block modifying section 40 will be described in detail. It is understood, however, that such description may apply to the other channels 42 forming the block modifying section 40. As depicted, the channel 50 is generally v-shaped and extends inwardly from the plane of the block modifying section 40 to a predetermined depth 52. As will be appreciated by those skilled in the art, the particular depth and width of the channel 50 may be varied as desired.
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Preferably, the top thickness 28 is greater than the bottom thickness 32, so that the body 20 of the block texturing apparatus 10 forms a taper. The difference need not be great, and the resulting predetermined angle 34 may be relatively small, around the range of zero to ten degrees, but preferably the predetermined angle 34 is around one to five degrees with respect to the direction of movement 60 of a block as it is separated from a mold. The reason being that tilting or otherwise shifting the block modifying section 40 facilitates greater manipulation of a surface of a block as it is removed from a block, and also enables the channels of the block modifying section 40 to self-clean. In this regard, it is envisioned that the block texturing apparatus be adjustable relative to the mold, to enable changes to be made in the field. This could be achieved by providing adjustment screws or shims, or by using technologies and techniques known to the art (not shown). Thus, block surface textures could be tailored to a particular situation.
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Alternatively, a plurality of block texturing apparatuses 10, 12 may be used in conjunction with a mold enclosure. As depicted in both solid and dashed lines, the mold enclosure 72 now includes walls 80, 82 and 84. Here, the block texturing apparatuses 10 and 12 are arranged and oriented for use as division plates. In this situation, the rear surfaces of the block texturing apparatuses 10, 12 are in a confronting relation and the front surfaces are facing away from each other. Thus, the mold is able to form two blocks having textured surfaces. Other placements of the block texturing apparatuses within an existing mold are possible. For example, the rear surface block texturing apparatus 10 could be placed in confronting relation to wall 82 and the rear surface of block texturing apparatus 12 could be placed in confronting relation to wall 76. This would position the front surfaces of the block texturing apparatuses 10, 12 towards the interior of the mold such that the resulting mold would then be able to produce a block with opposing textured surfaces. It should be apparent, then, that any molded block may have one or more its surfaces textured by practicing the invention.
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One purpose of the shelf 62 is to assist in redistributing and/or repacking block material on the surface of a block as the block is removed from a mold. Another purpose of the shelf 62 is to reduce and/or soften striations that may be formed by the channel 50. It should be apparent to practitioners in the art that the shelf 62 effectively reduces the cross-sectional area of the channel 50, and that different amounts of reduction will result in different textures that are imparted to the surface of a block. Thus, it will be appreciated that the amount of cross-sectional reduction may be varied from channel to channel. Alternatively, the shelf 62 may be coplanar with the plane of the front surface 22 and extend substantially across the bottom thereof.
The transition surface 66 of the shelf 62 is, depicted as being angled with respect to the front surface 64, however, it is understood that this need not be the case. For example, the transition surface 66, may be orthogonally oriented with respect to the front surface 64. Generally, though, an angled transition surface 66 is preferred for ease of manufacture and cleaning. Alternatively, the front surface 64 of the shelf 62 may be substantially reduced to create an angled shelf that extends inwardly with respect to the plane of the block modifying section 40.
The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US01/43875 | 11/14/2001 | WO | 4/28/2005 |