The present invention relates to a ventilated building block construction and to mold components for a machine for making the block.
Currently, typical concrete ventilating blocks are formed with straight, internal passages extending vertically through the block, such that when plural blocks are stacked, a ventilating “chimney” is formed. These and other block constructions are well represented in the patent literature. For example, U.S. Pat. No. 2,137,153 discloses ventilated wall blocks that are stacked vertically in an alternately inverted orientation, establishing both vertical and horizontal vent passageways. In U.S. Pat. No. 7,096,634, a block is disclosed that, when stacked, creates vertical vents or cores. Still other block constructions are disclosed in U.S. Pat. Nos. 1,758,757; 2,624,193; and 4,823,530. A ventilated building block and mold core and stripper shoe components for forming the ventilated building block are described in a commonly-owned U.S. Pat. No. 7,757,451, the entirety of which is incorporated herein by reference.
The block described in the '451 patent includes an elongated center portion flanked by a pair of substantially parallel side walls oriented substantially perpendicularly to the center portion, the center portion having a first vertical wall and a second sloped wall. The sloped wall extends between a relatively thicker bottom wall of the center portion and a relatively thinner top wall. A horizontal shoulder extends across the sloped front wall at a height substantially equal to the height of the side walls, such that the shoulder lies in the same horizontal plane as the upper edges of the side walls. Accordingly, the upper portion of the block assumes a substantially triangular cross-sectional shape.
Another existing design is described in GB 782,754. The building blocks in the GB '754 patent are “precast” (as stated in the patent). Precast products are made by filling a mold with concrete and leaving it for a specific time (usually a minimum of 24 hours), or depending on the design of the item being precast, a couple of days, before stripping it from the mold. The GB '754 design would require anywhere from two to six days before stripping from the mold. The GB '754 design, however, cannot be manufactured on a conventional concrete block machine as the design requires an “upper” and a “lower” core block. The lower core block would prevent or make it impossible to strip the block from the mold as is done on a block machine.
In accordance with an exemplary but nonlimiting embodiment of this invention, there is provided a modified ventilated building block along with mold core and stripper-shoe components for a block manufacturing machine for forming the modified ventilated building block. In the modified block, the upper portion of the block between and above the side walls now may have a substantially square cross-sectional shape. The sloped wall may alternatively have a consistent slope from bottom to top. Additionally, the horizontal shoulder has been eliminated to facilitate manufacture. Still further, the upper portion may be slightly inwardly offset from the side walls.
The design can advantageously be made on an automated concrete block machine that is configured to produce a block depending on its design in seconds, e.g. ten seconds per cycle. Also, because the concrete is compressed under vibration, the block can be five to ten times stronger than the precast unit. This additional strength is also achieved by using less cement (the most costly factor in concrete) than its precast counterpart.
In order to manufacture the modified block, new mold core and stripper shoe components are illustrated and described herein.
In an exemplary embodiment, a mold assembly provides for machine molding a ventilated building block. The building block is cooperable with an adjacent building block in a stacked, inverted and reversed orientation relative to the adjacent building block. The building block may include an elongated center portion flanked by a pair of substantially parallel side walls oriented substantially perpendicularly to the center portion. The center portion may project upwardly beyond upper edges of the side walls, and the side walls may extend forwardly of a forward edge of the center portion. The mold assembly includes an outside division plate delimiting one of a rearmost side and a forwardmost side of the building block and an inside division plate delimiting one of the rearmost side and the forwardmost side of the building block. A core block portion is disposed between the outside division plate and the inside division plate and delimits a sloped front surface of the elongated center portion. A plate portion cooperable with the core block portion and disposed spaced from the one of the outside division plate or the inside division plate delimits the rearmost side of the building block and delimits a thickness of the center portion where the center portion projects upwardly beyond the upper edges of the side walls. A pair of return flanges positioned on opposite lateral sides of the core block portion delimit a width of the center portion where the center portion projects upwardly beyond the upper edges of the side walls. A stripper shoe assembly disposed outside of and above the return flanges delimits the upper edges of the side walls and a height of the center portion.
The plate portion may extend laterally beyond opposite side edges of the core block portion.
The stripper shoe assembly may include a stripper bar positioned adjacent the core block portion and delimiting the height of the center portion, and blocks positioned at opposite lateral ends of the stripper bar and oriented relative to the stripper bar such that the stripper shoe assembly defines a U-shape. The blocks delimit the upper edges of the side walls. The mold may also include a plunger to which the stripper shoe assembly is bolted that is displaceable relative to the outside division plate and the inside division plate. In one arrangement, each of the blocks includes two discrete block elements separately attachable to an underside of the plunger. The stripper bar may include a planar plate member that is thinner than the blocks, where the bar is generally rectangular in cross-section.
The core block portion and the plate portion may be shaped and positioned relative to each other such that the sloped front surface of the elongated center portion transitions to a vertical wall portion substantially where the elongated center portion projects upwardly beyond the upper edges of the side walls. In another arrangement, the core block portion and the plate portion are shaped and positioned relative to each other such that the sloped front surface of the elongated center portion extends from a bottom of the elongated center portion to a top of the elongated center portion.
The return flanges may be positioned relative to the core block portion and the stripper shoe assembly such that the elongated center portion is offset inwardly from the side walls.
The mold assembly may also include a center division plate interposed between the outside division plate and the inside division plate that defines two mold chambers for concurrently molding two building blocks.
The inside division plate may delimit the other of the rearmost side and the forwardmost side of the building block.
In another exemplary embodiment, a ventilated building block is manufactured using the mold assembly according to the described embodiments.
In yet another exemplary embodiment, a method of manufacturing a ventilated building block using the mold assembly according to the described embodiments includes the steps of positioning and securing the mold assembly in a mold box; pouring a block material into the mold box; vibrating the mold box; compressing the block material with the stripper shoe assembly; and stripping the molded ventilated building block from the mold assembly with the stripper shoe assembly. The vibrating step and the compressing step may be performed concurrently.
In still another exemplary embodiment, a ventilated building block is cooperable with an adjacent building block in a stacked, inverted and reversed orientation relative to the adjacent building block. The ventilated building block includes an elongated center portion flanked by a pair of substantially parallel side walls oriented substantially perpendicularly to the center portion, where the center portion projects upwardly beyond upper edges of the side walls, and where the side walls extend forwardly of a forward edge of the center portion. The elongated center portion includes a sloped front face and a substantially vertical rear face, where the sloped front face is oriented at an initial angle relative to the substantially vertical rear face, with the initial angle being a maximum angle of the sloped front face relative to the substantially vertical rear face.
The invention will now be described in detail in connection with the drawings identified below.
With reference initially to
The center portion 12 of the block has a flat, substantially vertical back wall or rear face 18 and a generally-sloped front wall portion or front face 20. The back wall 18 is flush or co-planar with back (or first) edges 22, 24 of the side walls 14, 16, respectively. The sloped front wall portion 20 extends between a relatively thicker bottom wall or base 26 to a relatively thinner top wall 28. In one embodiment, the sloped front wall transitions to a vertical wall portion 21 at approximately the upper edges 30, 32 of the side walls. In an alternative embodiment, the sloped front wall has a consistent slope from bottom to top (shown in dashed line in
In this exemplary embodiment, the side walls 14, 16 extend beyond, i.e., forward of, the sloped front wall portion 20, and the lower (or third) edges 30a and 32a of the sidewalls are flush with the bottom wall or base 26.
In the exemplary but non-limiting implementation of the invention illustrated in
It will be understood that the dimensions of the block may vary uniformly by scale, or differentially, depending on specific applications. It will also be appreciated that the block may be constructed of any suitable building materials including in addition to concrete, such materials as metals, plastics, resins, etc.
Turning now to
With continued reference to
The stripper shoe assembly 58 includes the stripper bar 58A and blocks 58B. The blocks 58B are positioned at opposite lateral ends of the stripper bar 58A and are oriented relative to the stripper bar such that the stripper shoe assembly 58 defines a U-shape. The stripper bar 58A delimits a height of the center portion 12, and the blocks 58B delimit the upper edges of the side walls 14, 16. The plunger 56 to which the stripper shoe assembly 58 is bolted is displaceable relative to the outside division plate 54 and the inside division plate 52.
The core block portion 62 and the plate portion 60 may be shaped and positioned relative to each other such that the sloped front surface 20 of the elongated center portion 12 transitions to the vertical wall portion 21 substantially where the elongated center portion 12 projects upwardly beyond the upper edges of the side walls 14, 16. The core block portion 62 and the plate portion 60 may be shaped and positioned relative to each other such that the sloped front surface 20 of the elongated center portion 12 extends from a bottom of the elongated center portion to a top of the elongated center portion (shown in dashed line in
For all embodiments, it will be appreciated that the dimensions of the core and stripper components may vary depending on the dimensions of the finished block 10. The core plate portion 60 or 60A may be placed anywhere on the upper edge of the core block portion 50, and return flanges 61 or 61A may vary in both length and height.
As well understood by those familiar with the Besser and Columbia machines, in the block manufacturing process, a pallet plate (not shown) is moved into position below the mold box 42, and concrete is poured into the box. The mold box 42 is vibrated to settle and uniformly distribute the concrete, and then the plunger head 56 and stripper shoe assembly 58 as described herein will be moved into the box to compress the concrete while under vibration, within the confines of the inner and outer division plates 52, 54, end liners (not shown) and about the core 50. After the block 10 has been formed, it will be stripped from the mold by removing the pallet, enabling the stripper shoe and plunger head to push the finished product out of the mold box.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/878,294, filed Sep. 16, 2013, the entire content of which is herein incorporated by reference.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/IB14/02044 | 9/16/2014 | WO | 00 |
Number | Date | Country | |
---|---|---|---|
61878294 | Sep 2013 | US |