Patent Grant
9957687
This invention relates generally to wall blocks, and walls constructed from the wall blocks. This invention also relates to mold boxes and forming members for the mold boxes in the manufacture of the wall blocks.
Retaining walls are used in various landscaping projects and are available in a wide variety of styles. Numerous methods and materials exist for the construction of retaining walls. Such methods include the use of natural stone, poured concrete, precast panels, masonry, and landscape timbers or railroad ties.
In recent years, segmental concrete retaining wall units, which are dry stacked (i.e., built without the use of mortar), have become widely accepted in the construction of retaining walls. Such retaining wall units have gained popularity because they are mass produced and, consequently, relatively inexpensive. They are structurally sound, easy and relatively inexpensive to install, and couple the durability of concrete with the attractiveness of various architectural finishes.
The shape of the block is also an important feature during installation of a retaining wall. Many commercially available blocks are symmetrical about a plane bisecting the front and back surfaces. Typically such blocks have planes rather than axes of symmetry, as there are differences between the top and bottom surfaces of such blocks. Clearly, blocks that are substantially square or rectangular (i.e., each surface being joined to another at an orthogonal angle) exhibit a great deal of symmetry. There are advantages to having non-parallel surfaces on these blocks when constructing a retaining wall. The angles formed by these side surfaces permits construction of curvilinear walls, and moreover, permit the amount of curvature to vary according to the terrain and desired appearance of the retaining wall.
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. 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.
Additionally during the manufacture of the block, separate core support bridges (similar to core bars) help support interior void forming elements such as open cores, pin holes and the like, which span the cavity of the mold during production and allow the concrete to flow around and under these support bridges. Regular over the top of mold core bars may leave undesired troughs or blemishes on the surface of the block where the core bars pass over the face or surface area of the block. Numerous core bars in a mold may result in inconsistent material distribution inside the mold cavity and can create problems in achieving good compression results in the concrete material.
Another important feature of retaining wall blocks and blocks used in free standing walls is the appearance of the block. Creating a uniform and consistent look is very appealing for walls. Additionally, 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 single large unit in the mold cavity and providing one or more splitting grooves in the single unit to function as one or more splitting planes. The single unit 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. 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.
Wall block systems are also generally provided with some means to connect blocks in adjacent courses of the wall, such as a pinning system. The pinning system generally connects adjacent courses in a wall together thereby strengthening the wall and increasing stability of the structure. The pinning system can also align the courses of adjacent blocks to produce a set-back or a near vertical wall.
It would be desirable to provide a wall block having full depth cores which lighten the block weight for use in constructing a wall, retaining wall, fence or the like.
It would be desirable to provide a wall block having a chamfer on the sides and top of the front face of the block, to reduce the probability of sustaining damage to the block edges during manufacture, plant-handling, transportation and site installation handling. It would further be desirable that the sides and top of the front face of the wall block have an angled chamfer which creates block edges that are greater than 90° from a vertical plane formed from the sides and front of the block. The greater than 90° edges are harder to chip off or wear away during manufacture, plant-handling, transportation and site installation handling, and thereby minimize any damage to block edges.
It would be desirable to provide a system of blocks for constructing a wall that combines the ease of installation of modern segmental wall blocks with the attractive appearance of an aesthetic design. It would also be desirable to provide a retaining wall system that allows an aesthetically pleasing uniform appearance.
It would further be highly desirable to have a wall block system which can be used to build a retaining wall using a pin connection between courses, depending on the requirements of the project. Such a unit would also be desirable from a production and distribution view point, because the same block design could be used in multiple wall applications, thus reducing the need to produce specialty units.
It would be further desirable to provide a wall block system for the construction of a wall, retaining wall and the like having a pin connection system whereby the courses of the wall being constructed are aligned by a core of the block when the inserted pin of the pinning system engages a wall of the core of the block. This method of supporting the pin core is also a benefit in that it eliminates the need for additional core bars or supporting bridges.
It would be further desirable to provide a wall block system for the construction of a wall, retaining wall and the like having a pin connection system that may allow setback of the structure being constructed. It would be further desirable to provide a wall block system for the construction of a wall, retaining wall and the like having a pin connection system that may allow near vertical construction of the structure.
It would further be desirable to provide a mold box utilizing a recessed forming member to produce a core rather than a standard core bar as known in the art. It would further be desirable to provide a mold box utilizing a recessed forming member that can produce a core and a pin hole. It would further be desirable to provide a mold box utilizing a recessed forming member that can produce a core, pin hole and receiving channel.
A wall block including a block body having opposed front and rear faces, opposed first and second side walls, and opposed and substantially parallel top and bottom surfaces. The wall block also including at least one core extending from the top surface to the bottom surface, having opposed front and rear surfaces and first and second side walls. The wall block including at least one pin hole opening onto the top face of the block and extending at least a portion from the top surface to the bottom surface, the at least one pin hole opening into at least a portion of at least one surface of the at least one core.
The front face of the wall block may have an angular surface that is adjacent and non-orthogonal to the top surface. The front face may also have an angular surface that is adjacent and non-orthogonal to at least one of the opposed first and second side walls. The front face may also have an angular surface that is adjacent and non-orthogonal to the first side wall and has an angular surface that is adjacent and no-orthogonal to the second side wall.
The wall block may further include two cores having opposed front and rear surfaces and first and second side walls. The wall block may further include that the top surface has a first and a second elongate channel, the first elongate channel extending from the first side wall of the core to the first side wall of the block body and the second elongate channel extending from the second side wall of the core to the second side wall of the block body. The wall block may further include that the top surface has first, second, third and fourth elongate channels, the first elongate channel extending from the first side wall of the first core to the first side wall of the block body, the second elongate channel extending from the second side wall of the first core to the second side wall of the block body, the third elongate channel extending from the first side wall of the second core to the first side wall of the block body and the fourth elongate channel extending from the second side wall of the second core to the second side wall of the block body.
The pin hole of the wall block may open onto the rear surface of the core. The wall block may further include at least two pin holes, wherein at least one pin hole opens into at least a portion of at least one surface of the first core and at least one pin hole opens into at least a portion of at least one surface of the second core.
The wall block may include that the opposed first and second side walls are non-orthogonal to the front and back faces.
A wall block including a block body having opposed front and rear faces, opposed first and second side walls, and opposed and substantially parallel top and bottom surfaces. The wall block further includes at least one core extending from the top surface to the bottom surface, the at least one core having opposed front and rear surfaces and first and second side surfaces and at least one pin hole opening onto the top surface of the block and extending at least a portion of the distance from the top surface to the bottom surface, the at least one pin hole opening onto at least a portion of at least one surface of the at least one core.
The wall block may include that the front face has an angular surface that is adjacent and non-orthogonal to the top surface and may further include that the front face has at least one angular surface that is adjacent and non-orthogonal to at least one of the opposed first and second side wall. The wall block may further include that the front face has an angular surface that is adjacent and non-orthogonal to the first side wall and has an angular surface that is adjacent and no-orthogonal to the second side wall or the wall block may include that the front face has at least one angular surface that is adjacent and non-orthogonal to at least one of the opposed first and second side walls.
The wall block may include that the top surface has a first and a second elongate channel, the first elongate channel extending from the first side surface of the core to the first side wall of the block body and the second elongate channel extending from the second side surface of the core to the second side wall of the block body.
The wall block may include two cores having opposed front and rear surfaces and first and second side surfaces and the wall block may further include that the top surface has first, second, third and fourth elongate channels, the first elongate channel extending from the first side surface of the first core to the first side wall of the block body, the second elongate channel extending from the second side surface of the first core to the second side wall of the block body, the third elongate channel extending from the first side surface of the second core to the first side wall of the block body and the fourth elongate channel extending from the second side surface of the second core to the second side wall of the block body. The wall block may further include that the at least one pin hole is two pin holes that open onto the rear surface of the first core or may include that the at least one pin hole is two pin holes that open onto the first and second side surface of the first core.
The wall block may include that the opposed first and second side walls are non-orthogonal to the front and back faces.
A wall block including a block body having opposed front and rear faces, opposed first and second side walls, and opposed and substantially parallel top and bottom surfaces, the opposed first and second side walls being non-orthogonal to the front and back faces, the front face of the block having a front portion substantially parallel to the opposed rear face, a first angled portion extending non-orthogonal from the top surface, a second angled portion extending non-orthogonal from the first side wall and a third angled portion extending non-orthogonal from second side wall. The wall block further includes at least one core extending from the top surface to the bottom surface, having opposed front and rear surfaces and first and second side surfaces and at least one pin hole opening onto the top face of the block and extending at least a portion of the distance from the top surface to the bottom surface.
The wall block may include that the top surface has a first and a second elongate channel, the first elongate channel extending from the first side surface of the core to the first side wall of the block body and the second elongate channel extending from the second side surface of the core to the second side wall of the block body.
The wall block may include two cores having opposed front and rear surfaces and first and second side surfaces and the wall block may further include that the top surface has first, second, third and fourth elongate channels, the first elongate channel extending from the first side surface of the first core to the first side wall of the block body, the second elongate channel extending from the second side surface of the first core to the second side wall of the block body, the third elongate channel extending from the first side surface of the second core to the first side wall of the block body and the fourth elongate channel extending from the second side surface of the second core to the second side wall of the block body. The wall block may further include that the at least one pin hole is two pin holes that open onto the rear surface of the first core or may include that the at least one pin hole is two pin holes that open onto the first and second side surface of the first core.
A mold assembly for use in producing wall blocks including a horizontally oriented planar bottom member, first and second opposing side walls each having at least one groove on a top surface and first and second opposing end walls. The mold assembly further including a center wall having at least one groove on a top surface, the center wall having a first end adjacent the first end wall and a second end adjacent the second end wall, the first side wall, end walls and center wall being joined to form a first mold cavity, the second side wall, end walls and center walls being joined to form a second mold cavity, the bottom member enclosing a bottom of the first and second mold cavities, a top of the first and second mold cavities being open. The mold assembly further including at least two forming members each having core forming portions, at least one forming member positioned in the first mold cavity and having a first end accepted into the at least one groove of the first side wall and a second end accepted into the at least one groove of the center wall, and at least one forming member positioned in the second mold cavity and having a first end accepted into the at least one groove of the center wall and a second end accepted into the at least one groove of the second side wall.
The mold assembly may further include that the at least two forming members each have at least one pin hole forming portions and may further include that the at least two forming members have channel forming portions.
The mold assembly may include that the at least one groove on the top surface of the side walls and center wall is at least two grooves, the at least two forming members is at least four forming members with at least two forming members positioned in the first mold cavity and at least two forming members positioned in the second mold cavity. The mold assembly may include that the at least one groove on the top surface of the side walls and center wall is at least four grooves, the at least two forming members is at least eight forming members with at least four forming members positioned in the first mold cavity and at least four forming members positioned in the second mold cavity.
A method of making blocks including placing a mold over a horizontal pallet, the mold including first and second opposing side walls each having at least two grooves on a top surface, first and second opposing end walls, a center wall having at least two grooves on a top surface, the first side wall, end walls and center wall being joined to form a first mold cavity, the second side wall, end walls and center walls being joined to form a second mold cavity, the bottom member enclosing a bottom of the first and second mold cavities, a top of the first and second mold cavities being open, and at least four forming members each having a core forming portion, at least two forming members positioned in the first mold cavity and having a first end accepted into one of the grooves of the first side wall and a second end accepted into one of the grooves of the center wall, at least two forming members positioned in the second mold cavity and having a first end accepted into one of the grooves of the center wall and a second end accepted into one of the grooves of the second side wall. The mold also includes filling the mold cavities with a moldable material to form a first slab in the first mold cavity and a second slab in the second mold cavity and applying downward pressure with a stripper head assembly to remove the first and second slabs from the mold. The mold further including curing the first and second slabs, splitting the first slab into first and second blocks and splitting the second slab into third and fourth blocks, each of the first, second, third and fourth blocks having opposing and parallel first and second face surfaces, opposing first and second side walls, and at least one core.
The method may further include that the at least four forming members each have at least one pin hole forming portion and wherein each of the first, second, third and fourth blocks have at least one pin hole. The method may include that the at least one pin hole forming portion is two pin hole forming portions and wherein each of the first, second, third and fourth blocks have two pin holes. The method may include that the at least four forming members have channel forming portions and wherein each of the first, second, third and fourth blocks have at least one channel.
The method may include the at least two grooves on the top surface of the side walls and center wall is at least four grooves, the at least four forming members is at least eight forming members with at least four forming members positioned in the first mold cavity and at least four forming members positioned in the second mold cavity and wherein each of the first, second, third and fourth blocks have two cores. The method may further include that four of the forming members each have at least one pin hole forming portion and wherein each of the first, second, third and fourth blocks have at least one pin hole. The method may include that the at least eight forming members have channel forming portions and wherein each of the first, second, third and fourth blocks have at least one channel.
The method may include that the stripper head assembly has an angular plate that imprints an angular surface on the first and second slabs and wherein the first, second, third and fourth blocks have at least one angular surface.
A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings, wherein:
In this application, “upper” and “lower” refer to the placement of the block in a wall, retaining wall, fence and the like. The lower surface faces down, that is, it is placed such that it faces the ground. In forming a wall, one row of blocks is laid down, forming a course. A second course is laid on top of this by positioning the lower surface of one block on the upper surface of another block. The wall blocks of this invention may be symmetrical about a vertical plane of symmetry. The blocks are provided with pin holes and at least one core which may serve as a pin receiving cavity. The blocks may also be provided with a receiving channel. The location, shape, and size of the pin holes, optional receiving channels and core are selected to maximize the strength of the block, as described by reference to the drawings. It is also to be understood that the pin holes, receiving channels and cores in addition to pins described below could also be used on different block types and block shapes to form different walls and that the block shown with these features does not limit the scope of the invention.
An embodiment of the wall block is shown in
Block 100 includes openings or cores 114 and 115 that may extend from top surface 102 to bottom surface 103, or may only extend partially through block 100, i.e., open to top surface 102 but closed at bottom surface 103. Cores 114 and 115 divide block 100 into front portion 108, back portion 109 and center portion 110. Cores 114 and 115 reduce the weight of block 100. Lower block weight is both a manufacturing advantage and a constructional advantage when building a wall from the wall blocks as it reduces cost due to less material and makes lifting of the blocks easier. Cores 114 and 115 have opposed front and rear surfaces 172 and 174, respectively. Front surface 172 of each respective core being located in a closer proximity to front face 104 then rear surface 174 of each respective core. Rear surface 174 of each respective core being located in a closer proximity to rear face 105 than front surface 172 of each respective core. Cores 114 and 115 have first and second side walls 176 and 177. Core side walls 176 are located in proximity to side wall 106 and core side walls 177 are located in proximity to side wall 107. In the embodiment shown in
First and second pin holes 118 are located in center portion 110 and extend through block 100; open to top surface 102 and bottom surface 103. First and second pin holes 118 also open into the rear surface 174 of core 114, which is located in closer proximity to front face 104 than is core 115. The openings of pin holes 118 into rear surface 174 of core 114 extend from the top surface 102 towards the bottom surface 103 and form elongate slots 119 having a lateral width as measured in a direction between side walls 106 and 107 which is less than the maximum lateral width of the pin holes 118. The pins used with this block are dimensioned to fit within the pin holes but are larger than the opening of the pin hole into surface 174 so that the pin is securely retained within the pin hole. It should be understood that this is not limiting and that block 100 can be manufactured with the pin holes extending from top surfaces 102 through any desired distance toward bottom surface 103, i.e., open to the top surface but not open to the bottom surface. Further pin holes 118 may be manufactured to open into any surface of core 115 and/or any surface of core 114 or may be manufactured to be closed to both cores. The pin hole interior surfaces may be tapered from wider to narrower from the top surface to the bottom surface or its interior surfaces may be non-tapered or plumb. This taper of the surfaces of the pin holes is used in the manufacturing phase to help ease the removal of the block unit from the mold. The taper creates a draft angle which helps strip the pin hole forming core with greater ease from the block in the mold while helping to maintain the integrity of the shape of the pin hole. The pin holes 118 may be positioned such that they are located farther away from the line of symmetry S and closer to side walls 106 and 107. It should be noted that additional pin holes can be provided, if desired, so as to provide for further choices of predetermined setback when building a wall. Additionally, the location of the pin holes in the body of the block may be varied as desired and could, for example, be located in front portion 108, back portion 109 or neck portions 113. For example,
Pin holes are sized to receive pin 50 which is shown in
Top surface 102 has receiving channels 130 located in neck portions 113. Receiving channels 130 extend from side wall 106 to core side wall 176 of cores 114 and 115. Receiving channels 130 also extend from side wall 107 to core side wall 177 of cores 114 and 115. Thus, block 100 includes two channels extending through the entire length of the block body, from sidewall 106 through cores 114 and 115 and to side wall 107. Receiving channels 130 are located on the top surface 102 and are formed from a bridge styled core support or forming member that is mounted to a side wall or liner of a mold cavity. During the manufacturing of block 100, concrete or other desired material settles and is vibratory compacted around the forming member. The block is then stripped from the mold cavity, forming receiving channels 130, along with cores 114 and 115. Depending upon the application, receiving channels may be of sufficient width and depth as to accommodate a channel bar or other connection means for securing geogrid to the courses of blocks during construction of a retaining wall. Receiving channels 130 may also receive horizontal reinforcing materials such as rebar during the construction of a wall. It should be understood that in some applications where the pin hole extends from the top surface through to the bottom surface and where the front face may have a non-beveled (substantially flat) surface, the top and bottom surfaces of block 100 may be reversible. In other words, when block 100 is used in the construction of a wall either top surface 102 or bottom surface 103 may face downward. Thus, the head 52 of pin 50 may then also be received in some applications in the receiving channel as discussed further below. It should be noted that the shape, width and length of the channel can vary depending upon the application and could for example only extend a portion of the length of neck portion 113 or may open onto only one of side walls 106 or 107 or may open onto neither side wall.
Though the blocks illustrated in the
An alternate embodiment of the block is shown in
Block 200 includes front portion 208, back portion 209 and center portion 210. Block 200 also includes openings or cores 214 and 215 and may extend from top surface 202 to bottom surface 203, or may only extend part of the way through block 200. Cores 214 and 215 may also be utilized as pin receiving cavities. Block 200 also includes neck portions 213 adjacent side walls 206 and 207, extending from front portion 208 to center portion 210 and to back portion 209. First and second pin holes 218 are located in center portion 210 and extend a distance through block 200, open to top surface 202 but closed at bottom surface 203. The pin hole interior surfaces may be tapered from wider to narrower from the top surface to the bottom surface or its interior surfaces may be non-tapered or plumb. It should be noted that additional pin holes can be provided, if desired, so as to provide for further choices of predetermined setback when building a wall. Additionally, the location of the pin holes in the body of the block may be varied as desired and could, for example, be located in front portion 208, back portion 209 or neck portions 213.
An alternate embodiment of the block is shown in
Bottom surface 303 has receiving channels 330 located in neck portions 313 and receiving channel 331 in center portion 310. Receiving channels 330 extend from side wall 306 to core side wall 376 of core 315. Receiving channels 330 also extend from side wall 307 to core side wall 377 of core 315. Receiving channel 331 extends from side wall 306 through center portion 310 to side wall 307. Additionally, receiving channel 331 also extends from side wall 306 through rear surface 374 of core 314 to side wall 307. Thus, block 300 includes two channels extending through the entire length of the block body, from sidewall 306 through core 315 and to side wall 307 and from side wall 306 through center portion 310 and core 314 to side wall 307. Receiving channels 330 and 331 located on the top surface 302 are formed from a forming member that is mounted to a side wall or liner of a mold cavity. During the manufacturing of block 300, bottom surface 303 faces up and concrete or other desired material settles around the forming member and is allowed to set, the block is then stripped from the mold cavity, forming receiving channel 330. During construction of a wall with no setback, pins are placed in pin holes 318 of top surface 302 in a laid lower course of blocks 300. The upper portion of the pin or the head of the pin is received in channel 331 of the bottom surface of the upper course of blocks. Receiving channels 330 and 331 may receive horizontal reinforcing materials such as rebar during the construction of a wall. It should be noted that the shape, width and length of the channel can vary depending upon the application and could for example only extend a portion of the length of neck portion 313 or may open onto only one of side walls 306 or 307 or may open onto neither side wall.
An alternate embodiment of the block is shown in
First and second pin holes 718 are located in center portion 710 and extend through block 700; open to top surface 702 and bottom surface 703. First and second pin holes 718 may open onto the rear surface 774 of core 714. First and second pin holes 718 allow for a setback in the construction of a wall utilizing a pinning system with block 700. Third and fourth pin holes 719 are located in receiving channel 731 and extend from the lower surface of receiving channel 731 through block 700 opening onto bottom surface 703. Third and fourth pin holes 719 allow for a substantially vertical (or non-setback) constructed wall utilizing a pinning system with block 700. It should be understood that wall block 700 could be used to construct a wall with top surface 702 facing downward and wherein the receiving channels could also be utilized as pin receiving cavities in the construction of a wall.
It should further be understood that wall block 700 could have any desired dimensions. Block 700 may have, for example, a height (i.e., the distance between surfaces 702 and 703) of about 6 inches (152 mm), a body length of about 16 inches (406 mm) and a width of about 10 inches (254 mm).
When constructing a wall with geogrid reinforcement material G for walls which need geogrid to add a tensile soil reinforcing element to the mechanically stabilized earth, a base layer of blocks is laid and pins 50 are placed into pin holes 118 of top surface 102 of the blocks 100. The geogrid G may be made from a polyester knitted and/or woven synthetic material with a PVC or substantially similar compound coating, or they can be made with HDPE polyethylene materials. The layering of the geogrid G may be determined by engineering analysis as known in the art. When the type of geogrid has been accurately determined for its specific location in a wall the geogrid G is cut to length and placed over the block. It can be placed either over the connecting pins or the geogrid can be placed on the blocks first, and then the pins are put into the open pin holes on the top surface of the block to connect the geogrid to the blocks. The geogrid soil reinforcement material G is thus connected to pins 50 and pulled taut (towards the backfill embankment). The heads 52 of pins 50 are then received in cores 114 in the bottom surfaces of the upper adjacent course of blocks. The cores of the blocks and 6 inches behind the wall may be filled in with crushed stone for drainage and hydrostatic load bearing of the wall. The crushed stone interlock between courses of wall blocks improves pull out resistance and increases connection strength of the geogrid G. When the desired height of the wall is achieved a cap or finish layer 30 may be added.
Additionally or optionally, it should be understood that the geogrid reinforcement material G may be laid over the desired course of blocks and a channel bar or other geogrid securing means may be inserted into one of the receiving channels 130 of block 100. The geogrid soil reinforcement material may then be pulled towards the backfill embankment securing the channel bar or other geogrid securing means within the receiving channel and an upper adjacent course of blocks may then be laid.
It should further be noted that in some applications having limited or no set back and substantially vertical alignment and the height of the wall is such that the structure need further stabilization, vertical reinforcing members such as rebar, may be threaded through vertical open cores (columnar cavities) created by the cores of blocks as they are stacked one upon the other. It should further be noted that the wall may be constructed with two or more sizes of block as desired for a more random appearance of the wall aesthetic depending upon the application.
Center frame wall 20 spans end frame walls 6 and 8 of mold box 10 and has a compound shape. Center frame wall 20 along with first and second side frame walls 2 and 4 and opposing first and second end frame walls 6 and 8 may be formed, machined or flame cut during the manufacture of the mold box to form a single, continuous and seamless mold. Alternatively, the ends of center frame wall 20 may be securely or removeably fixed to end walls 6 and 8 in a conventional manner and the compound shape may be formed from removeable side liners as is known in the art. Further, first and second side frame walls 2 and 4 and opposing first and second end frame walls 6 and 8 may also be separate pieces that are securely or removeably fixed to one another in a conventional manner. The location of center frame wall 20 defines first and second mold cavities 22 and 24. Mold cavities 22 and 24 form paired blocks or block shapes with identical lengths, heights and widths. The paired blocks are split along their front faces from their opposite or mirror image block after removal from the mold to produce four blocks.
The blocks are oriented in the mold box such that the front faces of the blocks, prior to splitting, are generally parallel to end frame walls 6 and 8 and perpendicular to the direction of travel of the feed drawer and cut-off bar represented in
As shown in
As can be seen in
As can be seen in
Forming member 62 has core forming portion 64. Core forming portion 64 molds core 215 of block 200 and may be tapered from a wider dimension at the top of the mold to a narrower dimension at the bottom of the mold. It should be noted that the dimensions of the core forming portion is not limiting and could be any desired dimension depending upon the application. Further, core forming portion 64 could be designed to extend any distance through the mold cavity and thus could create a block where core 215 is open to top surface 202 but closed on bottom surface 203. Forming member 62 is substantially similar to forming member 32 except that it does not have channel forming bridge portions 36.
Mold box 10 is configured to rest upon a pallet to form mold cavities 22 and 24. Masonry material is deposited into cavities 22 and 24 by the feed drawer as it passes over the mold box. Excess material is removed by the cut-off bar as the feed drawer moves away from the mold box so that the masonry material is level with the top of the mold box and the top surfaces of the forming members. Next, stripper shoes (shown and described in connection with
The masonry material used in the production of the blocks 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, composite materials such as fiberglass or polymers, and stone. A vibratory action and stripper shoes on the mold head assembly can compress the material contained within the mold cavities.
It should be understood that the mold box could be configured to impart any desired face shape, texture or pattern onto any or all side, front and back surfaces of the blocks. The mold box could be configured to have separate mold cavities for each block produced in the mold box, thus the front face could be manufactured with any desired pattern texture or shape and when stripped from the mold cavity would not need to be split like the paired block produced in mold cavities 22 and 24 of mold box 10. A desired pattern, texture or shape may be formed, machined or flame cut onto any or all of the desired surface(s) of the mold box to form or impart the pattern, texture or shape onto the surface of the block being manufactured. Additionally and/or alternatively, the texture, pattern or shape can be formed by the use of replaceable side, back and front liners as is known in the art.
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 appended claims, which follow. In particular, it is contemplated by the inventor that various substitutions, alterations, and modifications may be made to the invention without departing from the spirit and is 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.
This application is a continuation of U.S. Ser. No. 14/861,224, filed Sep. 22, 2015, which is a continuation of U.S. Ser. No. 13/864,836, filed Apr. 17, 2013, now abandoned, which claims the benefit of U.S. Provisional Application No. 61/635,561, filed Apr. 19, 2012, entitled “Wall Block and Wall Block System”, the contents of each of which are hereby incorporated by reference herein.
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| Parent | 14861224 | Sep 2015 | US |
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