CA2167305A1 - Method of manufacturing a block - Google Patents
Method of manufacturing a blockInfo
- Publication number
- CA2167305A1 CA2167305A1 CA 2167305 CA2167305A CA2167305A1 CA 2167305 A1 CA2167305 A1 CA 2167305A1 CA 2167305 CA2167305 CA 2167305 CA 2167305 A CA2167305 A CA 2167305A CA 2167305 A1 CA2167305 A1 CA 2167305A1
- Authority
- CA
- Canada
- Prior art keywords
- block
- mold
- blocks
- angled
- platform
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
- B28B17/0027—Accessories for obtaining rubblestones
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C11/00—Details of pavings
- E01C11/22—Gutters; Kerbs ; Surface drainage of streets, roads or like traffic areas
- E01C11/221—Kerbs or like edging members, e.g. flush kerbs, shoulder retaining means ; Joint members, connecting or load-transfer means specially for kerbs
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Road Paving Structures (AREA)
- Revetment (AREA)
Abstract
The invention includes a method of molding one or more blocks (1, 84). The blocks (1, 84) are formed vertically in a mold (70). The top (78) of the mold (70) and compression shoes (110) have complementary angles to form one or more blocks (1, 84) having an angled end (16).
Description
WO 9S/32083 2 1 6 7 3 0 ~ PCT/US95/06166 -METHOD OF MANUFACTURING A BLOCK
BACKGROUND OF THE rNVENTION
1. Field of the Invention The present invention is directed to the field of l~n~1sc~ping and blocks used to construct a decorative and functional border, curb or edge, and a method of m~mlf~cturing the blocks. The present invention may be readily r~llor~ d onto existing common edging materials or installed 10 without use of such edging m~tçri~l~ The present invention also may be used as an edge restraint for use with paving stones or bricks or to provide decorative accent lines of contrasting color and texture in paver brick or stone in~t~ tions.
BACKGROUND OF THE rNVENTION
1. Field of the Invention The present invention is directed to the field of l~n~1sc~ping and blocks used to construct a decorative and functional border, curb or edge, and a method of m~mlf~cturing the blocks. The present invention may be readily r~llor~ d onto existing common edging materials or installed 10 without use of such edging m~tçri~l~ The present invention also may be used as an edge restraint for use with paving stones or bricks or to provide decorative accent lines of contrasting color and texture in paver brick or stone in~t~ tions.
2. Description of the Prior Art Numerous methods and materials exist for the construction of borders, curbs or edging for landscaping or site improvement work. Such borders, edges or curbs serve several func*ons. First, they are decorative, and provide an orderly transi*on from a garden area to a lawn, or from a lawn to a sidewalk, etc. Second, they serve to separate different areas with 20 di~lelll forms of plant life or other landscaping element~, thereby reducing m~inten~nce requirements such as removing weeds, or l-;.. ;l~g back plant life that would otherwise spread. Third, they can ease the process of lawn mowing by elimin~*ng the need to hand trim the border areas of the lawn after mowing the main areas with a mechanical lawn mower.
One method for the construc*on of edging~ for use around gardens or to divide sec*ons of a garden involves the use of lengths of flexible metal or plas*c edging m~tçri~l~ that are anchored by ~igging a trench, placing the edging m~teri~l anchoring the edging m~t~ri~l by driving spikes 216730~ -through it into the ground, and then filling the trench with dirt. Such methods are common and relatively inexpensive, but have several disadvantages. First, such materials do not have a natural, yet orderly appearance that is aesthetically pleasing in a landscaping application, 5 having inste~d a man-made appea~ ce. Second, such materials are not easily fixed in straight lines or measured curves due to their flexible nature.
Third, such materials are susceptible to damage during lawn mowing, and do not provide a "mowing strip" which would allow the wheels of a lawn mower to follow the contour of the edging and lessen the need for hand 10 L~ along the borders of the lawn. Four~, such edgin~ are susceptible to heaving from frost action in climates where the ground freezes.
Another method of providing an edging is the use of numerous natural stones or man-made bricks or blocks. Such stones or bricks are 15 installed by rli~ing a shallow trench and placing the stones or bricks more or less continuously along the length of the trench. Such m~tçri~l~ may also simply be placed on top of the ground without ~liggin~ a trench. Natural stone has long been used for this application, but lacks the advantages of the present invention for several reasons. First, natural stone is typically of 20 irregular shapes and requires labor intensive fitting of the natural stones along the border or edging or costly cutting of the pieces to fit. This irre~ rity also makes natural stone difficult to accommodate lawn mowing, and precludes the placement of a mowing strip. Bricks or rectangular blocks may also be used for lawn edging using a similar 25 in~t~ *on techniques. Rect~n~ r blocks do not lend themselves to the construction of curvilinear e-lgingc, which are found in most l~n(lsc~ping 2167~05 applications, because they must be cut to avoid gaps that may allow penetration of grass roots or other plant life and to provide an orderly appearance.
Another method for forming an edging or border has been to pour a 5 concrete edging in place. The disadvantages of this method are the expense and effort involved. To install such an e~lging an adequate trench must be dug, then forms must be constructed laying out the line of the edging, then the concrete must be mixed, poured, and allowed to cure. Such edgings may also require the placement of exp~n.cion material filled joints, and are 10 susceptible to cracking. Electrical wiling, as for outdoor lightin~ cannot bereadily installed in such structures, and if installed, cannot be m~intained and inspected without destruction of the edging In addition, such edgings are not readily removed in the event a change in the contour of the lawn or garden border is desired. Finally, such edgings do not provide a desirable 15 natural appearance.
There have also been efforts to address some of these deficiencies in the prior art through masonry block design~ and wet cast concrete designs that are meant specifically for use as an edgin~. These designs either are composed of single units that are capable of being laid in straight or curved 20 lines, or multiple unit systems with curved and straight pieces. These products are produced on concrete masonry block or paving m~c.hines7 or through pre-casting with numerous concrete forms, and are designed to allow the construction of curved edgings. These products, while an improvement over using a simple rectan~-lar brick, do not provide a natural 25 appearance due to their molded appearance from the m~mlfacturing process. None of these edges have a mowing strip incorporated as part of WO 9S/32083 ! ~ PCr/US95/06 166 216730'J
*s process design. Moreover, these ~eei~e cannot be lel orllled over an existing plastic or metal e~lging, and cannot accommodate elect~ical wires for inet~ tion of low voltage elect~ical lan-lsc~ping lights.
Another field in which the present invention may be used is the field 5 of curbs or edge r~sllai~ for surfaces that are paved with concrete or brick pavers or paving stones, or asphalt or concrete or other paving materials.
An example of curbing is disclosed in U.S. Pat. No. 4,971,475. Such curbing suffers from many of the limitAtions discussed above regarding e~lgin~ e.g., lack of curvilinear construction without time-consuming and 10 costly on-site cutting, susceptibility to heaving from freeze/thaw cycles, and inability for receiving electrical or other conduits.
Examples of paver stones are disclosed in U.S. Pat. Nos. 4,711,599 and 4,834,575. Typical paver edging lesl~ are plastic or metal strips fixed in a manner similar to the flexible edging materials discussed above.
15 For similar reasons, the paver edge l~ mls are also difficult to fix in straight mç~ellred curves, and are susceptible to heave from freeze/thaw cycles. Additionally, such les~ do not provide a conduit for drainage or elect~ical lines.
Another aspect of the present invention is a method of m~mlf~cturing 20 landscaping blocks having a groove and/or an angled end. Examples of masonry block molding are disclosed in U.S. Patent Nos. 5,062,610 and 4,335,549. However, these patents do not disclose how to mold blocks having an angled end and a split top surface.
Accordingly, it is an object of the present invention to provide a 25 landscaping block that is constructed with a groove or channel designed into the bottom surface of each landscaping block so that each block may be 2167~5 WO 9S/32083 rCI/US95/06166 ._ installed over prevalent exi~ting e~lgin~ or installed with or without inexpensive cormectors of a design disclosed herein.
Another object of the present invention is to provide a l~n~c~ping block that has a mowing or paver support edge on one or both sides of the 5 unit to ease lawn mowing or to provide an interlock ledge for the placement of pavers and surface to secure with a spike. This ledge or lip allows efficient lawn mowing in the vicinity of the e~lging This lip also serves as a base line for the screening off of the base material required for the installation of a layer of paving stones or bricks and provides an edge 10 structure that assures the integrity of the base layer of sand commonly used n(lçrnç~th the paving stones.
Another object of the present invention is to provide a landscaping block such that the uppermost surface of each unit has a natural stone appearance.
Another object of the invention is to provide a l~n~l~c~ring block with sides that taper from the lip to the bottom along the block's length to better resist the effects of frost heave, and to ease inct~ tion.
Another object of the invention is to provide a l~n~lsc~ping block with means to accommodate the passage of electrical wiring for outdoor 20 lighting A still further object of the invention is to provide a l~n~lsc~ping block that combines some or all of the elements of each of the various objects disclosed above.
Another object of the present invention is to provide a l~n~lsc~ping 25 block system that is constructed of blocks that are capable of forming either WO 95/32083 PCr/US95/06166 216730~
straight or curved edges, curbs or borders and incorporate some or all of the elements of each of the objects disclosed above.
Another object of the invention is a method of m~nllf~cturing l~n~l~c~ping blocks vertically in a mold and in pairs, where the top of each 5 block has a split surface.
These and other objects of the present invention will become app~ent with reference to the drawings, the description of the ple~lled embodiment and the appended claims.
SUMMARY OF THE INVENTION
In contrast to the prior art, the present invention provides for an improved landscaping block or edgin~ More particularly, the present invention relates to a landscaping block having a top and a generally opposed bottom, and first and second generally opposed sides, where each side extçntlc from the top to the bottom. The block further includes first 15 and second generally opposed ends, each end extending from the top to the bottom and from the first side to the second side. The first side includes a first upper face çxtenrling from the top downward to an inner edge of a first lip, and the first lip çxten~ outward from the first upper face to an outer edge of the first lip for alignment of the outer edge of the first lip with an 20 upper surface of a substrate when the block is inserted in the substrate.
Further, the block has a first lower face çxtenllin.~ from the outer edge of the first lip to the bottom. In accordance with a further aspect of the invention, the second side comprises a second upper face exten~ling from the top downward to an inner edge of the second lip. The second lip 25 extends outward from the second upper face to an outer edge of the second lip for alignment of the outer edge of the second lip with an upper surface WO9S/32083 2167~n~5 PCT/US9S/06166 of a substrate when the block is inserted into the substrate. Additionally, the second lower face extçn~ from the outer edge of the second lip to the bottom.
In accordance with a further aspect of the invention, the first lower face is tapered inward from the outer edge of the first lip to a first bottom edge of the first lower face, and the second lower face is tapered inward from the outer edge of the second lip to a second bottom edge of the second lower face.
In accordance with a further aspect of the invention, the block further comprises first and second generally opposed interior walls extçn~ing from the bottom toward the top, defining a groove opening into the bottom and sxtçn(ling from the first end to the second end. The groove may have different cross-sectional shapes as viewed from one of the ends.
In accordance with one embodiment of the invention, the groove has a generally rect~n~ r cross-sectional shape. In another aspect of the invention, the groove has a generally key-hole cross-sectional shape. In another aspect of the invention, the groove has a curved cross-sectional shape towards the top and a generally rect~n~ r cross-sectional shape adjacent the bottom.
In accordance with another aspect of the invention, the groove is tapered from the first end to the second end. In accordance with another aspect of the invention, the first end defines an acute angle ~om the first side to the second side and the second end is generally perpendicular to the first and second sides. Preferably, the acute angle is in the range from ten to ei~hteen degrees. Additionally, the first and second lips extend at least one-fourth inch from the inner edge.
WO 95132083 . ~ PCI/US95/06166 216730~
In accordance with another aspect of the invention, a l~nrlec.~ping system is provided. More par~icularly, the system relates to means for anchoring landscaping blocks in a fixed position relative to a substrate having an upper surface, the anchoring means being partially embedded in 5 the substrate. The system further includes one or more l~n~lsc~ping blocks, each of the blocks cnmpri.cing a top and a generally opposed bottom, first and generally opposed sides, each side extçn-ling from the top to the bottom, first and second generally opposed ends, each end extçn~ling from the top to the bottom and from the first side to the second side, and the 10 bottom comprising means for coupling the blocks with the anchoring means by receiving the ançhoring In accordance with another aspect of the invention, a plurality of landscaping blocks are provided, where each of the blocks comprised as a top and generally opposed bottom, first and second generally opposed sides, 15 each side çxtçntling from the top to the bottom, first and generally opposed ends, each end çxt~n-ling from the top to the bottom and from the first side to the second side, the bottom compri.~ing first and second generally opposed interior walls ext~n-ling from the bottom toward the top, ~lefining groove opening into the bottom and çxten-ling from the first to the second 20 end. Further, the blocks are placed end to end, the bottom of each block embedded in the substrate having an upper surface, the top of each block above the substrate upper surface, and the blocks defining an edging and the block grooves ~l~fining a con*nllous conduit.
In accordance with another aspect of the invention, a l~n~1ec~ping 25 system is provided having means for coupling landscaping blocks in an end to end relations_ip with a plurality of blocks, each of the blocks compri~in~;
WO 9S/32083 2 1 6 7 3 0 ~ PCT/US95tO6166 _ 9 _ a top and a generally opposed bottom, first and second generally opposed sides, each side exten-ling from the top to the bottom, first and second generally opposed ends, each end extçn-1ing from the top to the bottom and from the first side to the second side, the bottom comprising first and 5 second generally opposed interior walls exten~ling from the bottom toward the top ~lçfining a groove opening into the bottom and extçntling from the first side to the second side. The blocks are positioned end to end and embedded in a substrate, and adjacent ends of adjacent blocks are connected by coupling means ext~ntling into the grooves of the adjacent 10 blocks.
In accordance with another aspect of the invention, there is a method of molding a block comprising a top and a generally opposed bottom, first and second generally opposed sides, each side extending from the top to the bottom, first and second generally opposed ends, each end ext~on~ing from 15 the top to the bottom and from the first to the second side, wherein the first end defines an acute angle from the first side to the second side and the second end is generally perpendicular to the first and second sides. The method comprises the steps of positioning a platform in a mating position under a mold. The mold cnmpri~es a top, a bottom, and a continuous 20 vertical wall ext~nl1ing from the mold top to the mold bottom ~çfining a volume open at the top of the mold and further ~efining the cross-sectional shape of the block. The inner wall comprises a first pair of opposed side - walls defining the top and bottom of the block, and a second pair of opposed side walls ~lefining the first and second sides of the block. The 25 second pair of opposed side walls are angled at the top of the mold to define the first angled end of the block and the platform, positioned at the WO 9S/32083 ! PCT/US95/06166 216730~
bottom of the mold, defines the second end of the block. Additionally, the method includes introducing a block forming substance into the volume and colllp,~ssing the block forming substance in the volume from the top of the mold with a shoe having an angle that is complementary to the angled top 5 end of the second pair of opposed side walls of the mold. Additionally, the method includes the steps of moving the platform into a de-molding position away from the mold and removing the shoe to leave the molded block. The method may further include vibrating the mold and platform after introducing a block-forming substance into the volume. Further, the 10 mold may comprise a plurality of volumes.
In accordance with another aspect of the invention, there is a method of m~kin~ a first and second block, each block comprising a top and a generally opposed bottom, first and second generally opposed sides, each side extending from the top to the bottom, first and second generally 15 opposed ends, each end extending from the top to the bottom and from the first to the second side, wherein the first end defines an acute angle from the first side to the second side and the second end is generally perpendicular to the first and second sides. The method comprises the steps of positioning a platform in a mating position under a mold. The mold 20 comprises a top, a bottom, and a continuous vertical wall extending from the mold top to the mold bottom defining a volume open at the top of the mold and further defining a composite block having the cross-sectional shape of the first and second block position so that the top of the first block is parallel and connected to the top of the second block and the angled first 25 ends of the first and second blocks are at the top of the mold, wherein the inner wall comprises a first pair of opposed sidewalls ~lefining the bottom wo ss/32os3 - 11 2 1 6 7 3 0 ~ PCT/US95/06166 of the first block and bottom of the second block, and a second pair of opposed sidewalls defining the first and second sides of the f~rst and second blocks, the second pair of opposed sidewalls angled at the top of the mold to define the first angled end of the first and second blocks, and the platform at the bottom of the volume defining the second end of the first and second blocks. Additionally, the method includes introducing a block forming substance into the volume and co~llp~cssing the block-forming substance in the volume from the top of the mold with a shoe angled compl~ment~ly to the angled top end of the second pair of opposed sidewalls of the mold. Additionally, the method includes moving the platform into a de-molding position away from the mold and removing the shoe to leave the composite block. Additionally, the method may further inchlde splitting the composite block along the plane of the cormected tops of the first and second blocks forming the separate, disconnected first and second blocks. The method may further include vibrating the mold and platform. Further, the mold may comprise a plurality of volumes. Further, the block may be split by a splitting m~chine comprising a top splitting blade having a serrated lower edge. Further, the ~dj~cent blocks remain adjacent as a result of splitting the composite block.
DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of a landscaping block in accordance with the invention.
Figure 2a is an end view of a l~nd~c~ping block in accordance with the invention.
Figures 2b-2f are partial end views of ~lt~rn~te embotlimentc of a landscaping block in accordance with the invention.
WO9S/32083 ~ - 12 - PCT/US95106166 216730~
Figure 2g is an end view of a l~n-lsc~ring block inserted into a substrate in accordance with the invention.
Figures 3a-3c are end views of ~lt~ te embo~imçnt~ of a landscaping block showing the groove in accordance with the invention.
5Figure 3d is an end view of a l~n~lsc~ping block positioned over a pipe in accordance with the invention.
Figure 3e is an end view of a landscaping block positioned over electrical wiring in accordance with the invention.
Figure 4a is a perspective view of anchoring means in accordance 10withtheinvention.
Figure 4b is a perspective view of an alternate embodiment of anchoring means in accordance with the invention.
Figure 5a is a top view of a landscaping block in accordance with the invention.
lSFigure Sb is a top view of an alternate embodiment of a lan~cc~ring block in accordance with the invention.
Figure 5c is a top view of landscaping blocks aligned end to end to form a straight border in accordance with the invention.
Figure 5d is a top view of l~n(15c~ping blocks aligned end to end to 20form a curved border in accordance with the invention.
Figure 5e is a top view of landscaping blocks aligned end to end to form a curvilinear border in accordance with the invention.
Figure 6a is a perspective view of a l~ndsc~I)ing block system in accordance with the invention.
25Figure 6b is a perspective view of an ~ltern~te embodiment of a landscaping block system in accordance with the invention.
woss/320s3 2 1 6 73 0 5 PCT/US95/06166 Figure 6c is a perspective view of an ~ltçrn~*ve embodiment of a landscaping block system in accordance with the inven*on.
Figure 7 generally shows the steps of ...~ r~cturing the l~n~lsc~ping blocks of the present inven*on.
Figure 8 is a front view of a block molding m~chine.
Figure 9 is a perspec*ve view of an embodiment of the mold and platform of the present inven*on.
Figure lOa is a top view of an embodiment of the mold of the present invention.
Figure lOb is a top view of an ~ltçrn~te embodiment of the mold of the present inven*on.
Figure 11 is a sectional view of an embodiment of the mold along line x-x of the present inven*on.
Figure 12 is a perspective view of the compression head and shoe ~csembly of the present invention.
Figure 13 is a side view of the shoes of the present invention.
Figure 14 is a partial front view of the cut-offbar of the present invention.
Figure 15 is a front view of a splitter of the present invention.
Figure 16 is a top view of an alternate embodiment of the mold of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to Figures 1 - 6c there is shown a landscaping block 1 of the present invention. Block 1 is made of a rugged, weather-resist~nt m~teri~ crelably pre-cast concrete. Other suitable materials are plastic, reinforced fibers, wood, metal, and stone. As shown in Figure 1, block 1 WO 9S/32083 ~ - PCT/US95/06166 216730~
includes a top 2, a generally opposed bottom 3, and first and second generally opposed sides 4, 5, each side exten~ing from top 2 to bottom 3.
First and second generally opposed ends 6, 7 extend from top 2 to bottom 3 and from first side 6 to second side 7. Groove or channel 8 extends f-rom 5 bottom 3 into block 1 toward top 2, thereby having an opening at bottom 3, and ext~n(l~ from first end 6 to second end 7.
In a plcrellcd embodiment of the invention, block 1 extends a~pro,~;.,.~tely six inches from first end 6 to second end 7, four inches from top 2 to bottom 3, and four inches from first side 4 to second side 5 at lip 10 12. With these rlimen~ions, block 1 is light enough for relatively easy transport and placement, provides adequate separation height and width for edging, as well as providing a deep enough mower strip to reduce hand-l. ;.. ;-.g and allows for easy const~uction of a variety of straight and curved edging p~tt~rn.~. However, in order to meet the requirements of 15 dirre~cnl applicahons, block 1 may have larger or smaller limçn~ions and varymg proportlons.
As shown in Figure 2a, sides 4,5 each have an upper face 9 and a lower face 10. Upper face 9 is generally above-ground when the block is in use, providing the visual edging or separation. Lower face 10 is at and 20 below ground level and, in conjunction with groove 8, fixes block 1 in place in a substrate, typically dirt, sand, or other natural material.
Upper face 9 ext~n-ls from top 2 dowl,wald to inner edge 11 of lip 12. Face 9 may be planar and, in a prcfcllcd embo-lim~nt includes beveled edge 13 adjacent top 2. As shown in Figures 2b-2d, top 2 and face 9 may 25 have a variety of curved and/or textured shapes to meet the specific needs W O 95t32083 2 1 6 7 3 0 S P~rtUS95/06166 of any given application. Also, Figures 2e and 2f disclose alternate - embo-limçnt~ of block 1 with one or no lip 12.
Lip 12 defines a transition from upper face 9 to lower face 10.
Ledge 12 ext~ntls oulw~dly from upper face 9 to outer edge 14, at least 5 about one-fourth inch and ~efer~bly about five-eighths inch. As shown in Figure 2g, ledge 12 provides a mowing edge or strip that allows the wheels of a lawn mower to follow the conlou,~ of the block and allows the lawn mower to cut the grass adjacent the mowing strip, lessening the need for hand-l~ ng along the borders of a lawn.
In other applications of block 1, ledge 12: (1) provides an anchoring surface for placçrnent of l~n(lsc~pe rock, etc; (2) serves as a screed board leveling surface for paver in~t~ tions and provides interlock to prevent deterioration or loss of sub-base m~t~ri~ls when used as a paver curb or e~gin~ and (3) locks block 1 in place when used as an accent or passageway for conduit through a paved surface.
Fxt~n-ling dowllw~ud from outer edge 14 of ledge 12, lower face 10 has alignment strip 15 for easier placement of block 1 in the substrate and tapered portion 16 çxtentls to bottom edge 17. The adv~nt~ges of tapered portion 16 are discussed below.
As shown in Figure 1, groove or channel 8 extends into block 1 from bottom 3 toward top 2. In an embodiment shown in Figure 3a, groove 8 is defined by generally opposed interior walls 18a, 18b. The width of slot 8, - identifled by arrow D, is the distance between the opposed interior walls 18a, 18b and is wide enough to receive commonly available black plastic edging 19. As shown in Figures 4a and 4b, edging 19 may have various configurations. Typically, edging 19 have a lower bead or protrusion to WO 9S132083 - ~CI/US95/06166 allowing nailing or spiking in place. Figure 4a shows commonly available flexible black PVC edging or strip 20 having opposed vertical walls 21a, 21b, and a top 22 and a bottom 23 edge. As shown in Figure 4a, top edge 22 may include an elongated bead 24. As shown in Figure 4b, edging 19 5 may be a planar strip made of al----,;----"~ or other suitable material. F-l~ing 19 should be flexible to create the desired border shape and made of a suitable material for use in the desired substrate. Typically, edging 19 is partially embedded in a substrate by ~liggin~ a small trench, and also may be fixed in place by stakes.
Cavity 8 allows block 1 to fit over the top of and receive edging 19 or, as shown in Figure 3b, block 1 can be locked onto edging 20 by the key-hole cross-sectional configuration of slot 8. In the locking embodiment of Figure 3b, opposed interior walls 18a, 18b define an upper ~nn~ r receiving portion 25 for receiving the bead 24 of edging 20. Receiving 15 portion 25 has a lower opening that forms neck 26 which prevents bead 24 from moving downward out of upper receiving portion 25 without substantial force excee-ling the normal forces of the ~ulloullding substrate during freeze/thaw cycles. The lower portions of walls 18a, 18b preferably taper oulw~d or diverge towards sides 4, 5. Also, groove 8 can be tapered 20 from one end 6 to the other end 7, i.e., the slot width increases from one end 6 to the other end 7, for easier ~tt~çhment and det~.hment of block 1 to strip 20.
In the embodiment shown in Figure 3a, interior walls 18a, 18b are al)plo~ullately parallel, ~çfining a rect~n~ r region for receiving a planar 25 e~lging. In another embodiment shown in Figure 3c, interior walls define an WO 9Sr32083 2 1 6 7 ~ 0 5 PCT/US95/06166 upper curved shape at the top of groove 8 and a generally rect~n~ r cross-sectional shape ~ cent the bottom, accommodating a variety of edging~.
Groove or çh~nnel 8 accomplishes several goals. First, blocks 1 can be locked into place over exi~ting edging, which serves as an ~li nm~nt 5 guide, conce~ling the plastic or metal edging and providing an attractive, natural-looking edging Second, slot 8 provides connection, coupling, ~ligning, and anchoring means, ~ci~ting in the inst~ tion of the edging.
Finally, groove 8 allows for passage of pipe or other conduit for irrigation as shown in Figure 3d or electrical wiring as shown in Figure 3e along the edging In the embodiment of the invention shown in Figure 3b, tapered portion 15 of lower face 10 on sides 4, 5 and diverging interior walls 18a, 18b provide several advantages. First, this embodiment is more easily installed by allowing block 1 to be more easily inserted into the substrate or 15 soil than a flat bottomed surface. Second, this embodiment is more easily inserted over edging 19 and locked into place. Third, this embodiment is more resi~t~nt to frost heave than a flat bottomed surface, thereby ret~ ;..g its position in the substrate over a period of years. Finally, this embodiment allows block 1 to fit over pipes or conduits that would otherwise be too 20 wide.
The ends 6, 7 of block 1 provide another important aspect of the invention. In an embodiment of the invention shown in Figure 5a, end 6 is - angled a~l,roxi.. ~tçly 12 degrees from side 4 to side 5, while end 7 is ap~rox;.n~tely perpendicular to sides 4, 5. Figure 5b shows another 25 embodiment of block 1 having an angled end 6, but without lip 12. A
ple~,led range of angles is 10-18 degrees. As shown in Figures 5c - 5e, WO 95t32083 , `. ` PCT/US95/06166 216730~ 18-straight-end/angled-end block configurations allow for various straight (Figure 5c), curved (Figure 5d), curvilinear (Figure 5e) borders without having to cut the blocks at the installation site. At least nine diLrelenl shapes can be achieved using two blocks. In other embodiments, the blocks 5 may have both ends perpendicular to the sides, both ends angled from one side to the other, or ends with di~.~l-l angles. Plefelled angles are those divisible into 360 degrees (i.e. 9, 12, 15, 18 and 24 degrees) so that the blocks can make a circle to be used around a tree, for example.
There are numerous options for the appearance of top 2 and upper 10 face 9 of sides 4, 5. Any of these surfaces can have a natural or "split"
surface, smooth s~ ce, COldul-)y or other striated surface.
When block 1 is installed as shown in Figure 2e, block 1 is inserted into a substrate 40, which may be earth or other material. Lip 12, pler~lably planar, and iqlignment strip 15 assist in placing block 1 in a 15 ~le~llcd position wherein lip 12 is coplanar with the ~ulluu-lding substrate.Lip 12 provides a mowing or spacer strip that sep~les top 2 and sides 4, 5 from the substrate by the length of lip 12. Lip 12 may be on one or both sides of block 1 depending on the application.
A combination of blocks 1 can be used to create several l~n~l~c~ping 20 block systems. The first system is discussed above and shown schematically in Figure 6a. A new or existing edging 19 provides means for anchoring landscaping blocks 1 in a fixed position relative to the substrate 40. Anchoring means 19 is partially embedded in the substrate.
Using edging strip 20 disclosed in Figure 4a, bottom edge 23 is embedded 25 in the substrate and bead 24 is above the upper surface of the substrate.
The bottom groove or coupling means 8 at the bottom 3 of each block 1 is 2 1 6 7 3 0 r3 placed over and receives anchoring means 19 and the lower face 10 of each block 1 is also embedded in the substrate. The blocks 1 are aligned end to end along strip 19 thereby d~ning the l~n~1sc~ring border or e~ging Another system is to insert the blocks 1 in a substrate end to end 5 without using an edging 19, as shown in Figure 6b. Again, lower face 10 is embedded in the substrate and upper face 9 and top 2 define the edging above the substrate surface. Grooves 8 then form an interior conduit that can receive pipes, conduit, electrical wiring, or function alone as a drainage conduit.
Figure 6c discloses a third landscaping block system. The blocks 1 are inserted into substrate 40 end to end, thereby fixing the blocks 1 in the substrate. ~lignmçnt of the blocks is m~int~ined by use of connectors or coupling means 50 that connect the adjacent ends of the adjacent blocks.
For example, end 51 of block 60 is adjacent end 52 of block 61 and ends 51 15 and 52 are coupled by connector 50. The connectors can be tubing or a narrow strip that ~t~n~s from the upper portions of adjacent grooves.
Also, a single elongated tubing may pass through groove 8 from end to end the entire length of blocks.
The method of the present invention is shown generally in Figure 7.
20 First, the block-forming m~t~ri~l~7 typically water, cement, sand, and aggregate, are mixed and transported to a block molding m~hine. A wide variety of ~ lures are known to make blocks having various characteristics - such as strength, water absorbtion, density, shTink~ge, and other factors meeting ASTM standards and depending on the desired application of the 25 block. The ll~i~ e is l,lepared in any number of mixers known in the art.
The ll~i~lure is then placed in a hopper which transports the llli~ e to a 21673~c~
block molding m~hine shown generally in Figure 8. Any block molding m~c.hine known in the art`may be used. One m~chine found useful is the V3-12 Vibrapac, made by Besser Colllp~l~, Alpena, Michigan.
The llli~ e or fill is then poured or loaded into mold 70 sitting on 5 or mated with generally planar steel pallet 71 as shown in Figure 9.
Specific aspects of the mold are discussed further below. The top of mold 70 is then scraped with a cut-off bar to remove excess llli~lule. Mold 70 is then subjected to vertical compression by head 72 moving downward on top of mold 70. Further details of head 72 are provided below. Head 72 acts to 10 compress the fill within mold 70 for a period of time sufficient to form a solid, contiguous block. Generally, each block producing cycle has a duration of six to twelve seconds at a total load of 1500 to 2000 pounds.
Additionally, mold 70 and horizontal platform 71 may be agitated during compression.
Once the compression is complete, platform 71 is lowered vertically away from mold 70 into a de-molding or stripped position and head 72 pushes the newly molded blocks dowllwd~d through mold 70 so that they remain on platform 71. Head 72 is then raised vertically.
Once the blocks are formed, they are cured by various means known 20 in the art. Typically, blocks are cured in kilns for up to twenty-four hours under pressure and/or with steam. Once cured, the blocks may be split.
Splittin~ methods such as hand-splitting with h~mmer and chisel, and m~chine splitting are known in the art. Additional details of the splitter used in connection with the present invention are provided below. After 25 splitting, the blocks are palletized or otherwise packaged for .~hipment or storage.
wo ss/320s3 - 21 21 6 7 3 o ~ PCr/usg5/o6l66 The method of ~e present invention is more specifically directed to molding landscaping block 1, having angled first end 6. In order to more easily and efficiently make block 1, mold 70 and compression head 72 are used. A top view of an embodiment of mold 70 is shown in Figure lOa.
S Mold 70 has a front vertical wall 73, generally opposed back vertical wall 74, and generally opposed side walls 75a, 75b ~lefining a generally rect~n~ r, vertical outer wall or edge 76. Mold 70 further includes one or more volumes 77 extending from the top 78 to the bottom 79 of mold 70.
Volume 77 is defined by a continuous vertical wall 80, described further lO below. When mold 70 is placed on top of or mated with platform 71, volume 77 is open at the top 78 of mold 70, but closed at the bottom 79 of the mold by platform 71.
As shown in Figures 9 and lOa, block 1 is preferably molded vertically, i.e., the end 6 to end 7 dimension of block 1 is positioned 15 vertically in mold 70 from top 78 to bottom 79. Vertical wall 80, which delimits volume 77, defines the cross-sectional shape of block 1. Vertical wall 80 includes a first pair of opposed sidewalls 8 la, 8 lb and second pair of opposed sidewalls 82a, 82b.
Also as shown in Figure lOa, block 1 is ~lerelably formed in pairs.
20 For example, volume 83 in Figure lOa defines a composite block 84 which comprises a first block 85 and second block 86 pair. Vertical wall 80 is configured so that blocks 85, 86 are positioned top to top, i.e., top 2 of - block 85 is parallel and connected to top 2 of block 86 at plane 89. As will be discussed further below, composite block 84 is split along plane 89 to 25 form first block 85 and second block 86, each having a natural or split surface ~ea~ ce at top 2. The first pair of opposed sidewalls 81a, 81b WO 9S/32083 ~ - 22 - PCI/US95/06166 2167~
define bottom 3 of block 85 and bottom 3 of block 86, respectively. The second pair of opposed sidewalls 82a, 82b define sides 4, 5 of block 85 and sides 4, 5 of block 86.
When mold 70 is positioned in the molding position on platform 71, S the second end 7 of blocks 85, 86, respectively, is defined by platform 71.
The first angled end 6 of blocks 85, 86 are formed at the top 78 of mold 70.
As shown in the front view of mold 70, Figure 11, the top 78 of mold 70 has a saw-tooth or serrated shape. The angle of each side 100, 101 of top 99 defines the angle of the first end of each block 77 in the four respective 10 rows 99 of mold 70.
In one embo~limçnt mold 70 is formed by a solid block of steel, for example, with volume 77 m~hined out of the solid block.
In order to form angled end 6 on blocks 85, 86 in mold 70, co~ ression means 72 includes a plurality of shoes 110, with each shoe 110 fitting over the top of each volume 77 to form angled end 6. The general head 72 and shoe 110 configuration is shown in Figure 13.
As shown in Figure 14, the bottom 81 of each shoe 110 has an angle complementary to the desired angle of first end 6 of each molded block 1.
Therefore, when head 72 is compressed downward into mold 70 and each 20 shoe 110 co~ lesses into each volume 77, there is equal pressure across angled end 6, thereby forming a structurally sound angled end 6 on block 1.
As discussed above, block m~chines may include a cut-off bar to scrape excess concrete offthe top 78 of mold 70 and bottom of shoes 110.
As shown in Figure 15, one embo~1iment of cut-offbar 111 has a serrated 25 bottom edge 113 with angles complçmçnt~ry to the top 78 of mold 70. In another embo~imçnt cut-offbar 111 is generally rect~n~ r with planar WO 9S/32083 2 1 6 7 ~ Q 5 rcT/usgs/06l66 top and bottom edges. In use, this embodiment would move up and down following the collloul~ of the top 78 of mold 70 and shoes 110. In another embo-limçnt cut-off bar 111 may have flexible top and bottom edges.
In an ~ltern~te embo-liment volumes 77 in mold 70 are rotated 5 ninety degrees, as shown in Figure 10b. The angles on shoes 110 are also rotated ninety degrees to retain the same angled ends 6 on block 1. Cut-off bar 111 would then be generally rect~n~ r and move vertically as it passes over the top 78 of mold 70 to perform its scraping function.
Once composite block 84 is formed using mold 70 and head 72 10 described above, it is cured. After curing, block 84 is split. Figure 16 generally shows a splitter 115 that can be used with the present invention.
A top blade 116 and bottom blade 117 are used to split block 84 along the desired plane 89.
Since composite block 84 is molded having a top angled end, top lS blade 116 is serrated with angles that are complement~ry to the angled end of composite block 84. Since the bottom of composite block 84 is flat, bottom blade 117 is straight. When composite block 84 is positioned in splitter l lS so that blades 116 and 117 are co-planar with plane 89, bottom blade 117 is forced upward and top blade 116 is forced downward, thereby 20 applying generally equal pressure along plane 89 to split block 84 into blocks 85 and 86.
Additionally, as shown in Figure 10, sidewalls 82a, 82b may include v-shaped grooves 130a, 130b, respectively, that assists in providing a clean split along plane 89. Further, a v-shaped groove 131 can be provided at the 25 end of composite block 84 rlçfining ends 6 of blocks 85 and 86 to assist in providing a straight split at plane 89. Mold 70 in Figure 10a is configured WO 9S132083 ~ PCIIUS95/06166 21673~
so that when composite block 84 is split into separate blocks, the splitting process does not force adjacent blocks away from each other, thereby requiring additional h~ntlling or processing of the blocks. Referring to Figure lOa, when the first line of composite blocks, id~ntified as blocks A
S through D, are split, the angled end 6 on blocks A and D slopes downward toward walls 75a and 75b respectively. Therefore, blocks A and D do not fall away from blocks B and C.
In the embodiment of mold 70 shown in Figures 9 and 10, twelve pairs of blocks 1 are formed with each pair having a block 1 with an angled 10 end 6 complementary to the angled end 6 ofthe other block 1 of the pair, yielding twenty-four blocks per cycle. In a typical set-up, six to ten molding cycles may be completed per minute.
Mold 70 need not form block 1 in pairs. Figure 17 shows an ~ltern~te mold 120 where each volume 121 defines the cross-sectional 15 shape of a single block 1. In this embodiment splitter 115 is not required.
The above discussion provides various examples and embodiments of the invention and are not intended to limit the scope of the invention.
One method for the construc*on of edging~ for use around gardens or to divide sec*ons of a garden involves the use of lengths of flexible metal or plas*c edging m~tçri~l~ that are anchored by ~igging a trench, placing the edging m~teri~l anchoring the edging m~t~ri~l by driving spikes 216730~ -through it into the ground, and then filling the trench with dirt. Such methods are common and relatively inexpensive, but have several disadvantages. First, such materials do not have a natural, yet orderly appearance that is aesthetically pleasing in a landscaping application, 5 having inste~d a man-made appea~ ce. Second, such materials are not easily fixed in straight lines or measured curves due to their flexible nature.
Third, such materials are susceptible to damage during lawn mowing, and do not provide a "mowing strip" which would allow the wheels of a lawn mower to follow the contour of the edging and lessen the need for hand 10 L~ along the borders of the lawn. Four~, such edgin~ are susceptible to heaving from frost action in climates where the ground freezes.
Another method of providing an edging is the use of numerous natural stones or man-made bricks or blocks. Such stones or bricks are 15 installed by rli~ing a shallow trench and placing the stones or bricks more or less continuously along the length of the trench. Such m~tçri~l~ may also simply be placed on top of the ground without ~liggin~ a trench. Natural stone has long been used for this application, but lacks the advantages of the present invention for several reasons. First, natural stone is typically of 20 irregular shapes and requires labor intensive fitting of the natural stones along the border or edging or costly cutting of the pieces to fit. This irre~ rity also makes natural stone difficult to accommodate lawn mowing, and precludes the placement of a mowing strip. Bricks or rectangular blocks may also be used for lawn edging using a similar 25 in~t~ *on techniques. Rect~n~ r blocks do not lend themselves to the construction of curvilinear e-lgingc, which are found in most l~n(lsc~ping 2167~05 applications, because they must be cut to avoid gaps that may allow penetration of grass roots or other plant life and to provide an orderly appearance.
Another method for forming an edging or border has been to pour a 5 concrete edging in place. The disadvantages of this method are the expense and effort involved. To install such an e~lging an adequate trench must be dug, then forms must be constructed laying out the line of the edging, then the concrete must be mixed, poured, and allowed to cure. Such edgings may also require the placement of exp~n.cion material filled joints, and are 10 susceptible to cracking. Electrical wiling, as for outdoor lightin~ cannot bereadily installed in such structures, and if installed, cannot be m~intained and inspected without destruction of the edging In addition, such edgings are not readily removed in the event a change in the contour of the lawn or garden border is desired. Finally, such edgings do not provide a desirable 15 natural appearance.
There have also been efforts to address some of these deficiencies in the prior art through masonry block design~ and wet cast concrete designs that are meant specifically for use as an edgin~. These designs either are composed of single units that are capable of being laid in straight or curved 20 lines, or multiple unit systems with curved and straight pieces. These products are produced on concrete masonry block or paving m~c.hines7 or through pre-casting with numerous concrete forms, and are designed to allow the construction of curved edgings. These products, while an improvement over using a simple rectan~-lar brick, do not provide a natural 25 appearance due to their molded appearance from the m~mlfacturing process. None of these edges have a mowing strip incorporated as part of WO 9S/32083 ! ~ PCr/US95/06 166 216730'J
*s process design. Moreover, these ~eei~e cannot be lel orllled over an existing plastic or metal e~lging, and cannot accommodate elect~ical wires for inet~ tion of low voltage elect~ical lan-lsc~ping lights.
Another field in which the present invention may be used is the field 5 of curbs or edge r~sllai~ for surfaces that are paved with concrete or brick pavers or paving stones, or asphalt or concrete or other paving materials.
An example of curbing is disclosed in U.S. Pat. No. 4,971,475. Such curbing suffers from many of the limitAtions discussed above regarding e~lgin~ e.g., lack of curvilinear construction without time-consuming and 10 costly on-site cutting, susceptibility to heaving from freeze/thaw cycles, and inability for receiving electrical or other conduits.
Examples of paver stones are disclosed in U.S. Pat. Nos. 4,711,599 and 4,834,575. Typical paver edging lesl~ are plastic or metal strips fixed in a manner similar to the flexible edging materials discussed above.
15 For similar reasons, the paver edge l~ mls are also difficult to fix in straight mç~ellred curves, and are susceptible to heave from freeze/thaw cycles. Additionally, such les~ do not provide a conduit for drainage or elect~ical lines.
Another aspect of the present invention is a method of m~mlf~cturing 20 landscaping blocks having a groove and/or an angled end. Examples of masonry block molding are disclosed in U.S. Patent Nos. 5,062,610 and 4,335,549. However, these patents do not disclose how to mold blocks having an angled end and a split top surface.
Accordingly, it is an object of the present invention to provide a 25 landscaping block that is constructed with a groove or channel designed into the bottom surface of each landscaping block so that each block may be 2167~5 WO 9S/32083 rCI/US95/06166 ._ installed over prevalent exi~ting e~lgin~ or installed with or without inexpensive cormectors of a design disclosed herein.
Another object of the present invention is to provide a l~n~c~ping block that has a mowing or paver support edge on one or both sides of the 5 unit to ease lawn mowing or to provide an interlock ledge for the placement of pavers and surface to secure with a spike. This ledge or lip allows efficient lawn mowing in the vicinity of the e~lging This lip also serves as a base line for the screening off of the base material required for the installation of a layer of paving stones or bricks and provides an edge 10 structure that assures the integrity of the base layer of sand commonly used n(lçrnç~th the paving stones.
Another object of the present invention is to provide a landscaping block such that the uppermost surface of each unit has a natural stone appearance.
Another object of the invention is to provide a l~n~l~c~ring block with sides that taper from the lip to the bottom along the block's length to better resist the effects of frost heave, and to ease inct~ tion.
Another object of the invention is to provide a l~n~lsc~ping block with means to accommodate the passage of electrical wiring for outdoor 20 lighting A still further object of the invention is to provide a l~n~lsc~ping block that combines some or all of the elements of each of the various objects disclosed above.
Another object of the present invention is to provide a l~n~lsc~ping 25 block system that is constructed of blocks that are capable of forming either WO 95/32083 PCr/US95/06166 216730~
straight or curved edges, curbs or borders and incorporate some or all of the elements of each of the objects disclosed above.
Another object of the invention is a method of m~nllf~cturing l~n~l~c~ping blocks vertically in a mold and in pairs, where the top of each 5 block has a split surface.
These and other objects of the present invention will become app~ent with reference to the drawings, the description of the ple~lled embodiment and the appended claims.
SUMMARY OF THE INVENTION
In contrast to the prior art, the present invention provides for an improved landscaping block or edgin~ More particularly, the present invention relates to a landscaping block having a top and a generally opposed bottom, and first and second generally opposed sides, where each side extçntlc from the top to the bottom. The block further includes first 15 and second generally opposed ends, each end extending from the top to the bottom and from the first side to the second side. The first side includes a first upper face çxtenrling from the top downward to an inner edge of a first lip, and the first lip çxten~ outward from the first upper face to an outer edge of the first lip for alignment of the outer edge of the first lip with an 20 upper surface of a substrate when the block is inserted in the substrate.
Further, the block has a first lower face çxtenllin.~ from the outer edge of the first lip to the bottom. In accordance with a further aspect of the invention, the second side comprises a second upper face exten~ling from the top downward to an inner edge of the second lip. The second lip 25 extends outward from the second upper face to an outer edge of the second lip for alignment of the outer edge of the second lip with an upper surface WO9S/32083 2167~n~5 PCT/US9S/06166 of a substrate when the block is inserted into the substrate. Additionally, the second lower face extçn~ from the outer edge of the second lip to the bottom.
In accordance with a further aspect of the invention, the first lower face is tapered inward from the outer edge of the first lip to a first bottom edge of the first lower face, and the second lower face is tapered inward from the outer edge of the second lip to a second bottom edge of the second lower face.
In accordance with a further aspect of the invention, the block further comprises first and second generally opposed interior walls extçn~ing from the bottom toward the top, defining a groove opening into the bottom and sxtçn(ling from the first end to the second end. The groove may have different cross-sectional shapes as viewed from one of the ends.
In accordance with one embodiment of the invention, the groove has a generally rect~n~ r cross-sectional shape. In another aspect of the invention, the groove has a generally key-hole cross-sectional shape. In another aspect of the invention, the groove has a curved cross-sectional shape towards the top and a generally rect~n~ r cross-sectional shape adjacent the bottom.
In accordance with another aspect of the invention, the groove is tapered from the first end to the second end. In accordance with another aspect of the invention, the first end defines an acute angle ~om the first side to the second side and the second end is generally perpendicular to the first and second sides. Preferably, the acute angle is in the range from ten to ei~hteen degrees. Additionally, the first and second lips extend at least one-fourth inch from the inner edge.
WO 95132083 . ~ PCI/US95/06166 216730~
In accordance with another aspect of the invention, a l~nrlec.~ping system is provided. More par~icularly, the system relates to means for anchoring landscaping blocks in a fixed position relative to a substrate having an upper surface, the anchoring means being partially embedded in 5 the substrate. The system further includes one or more l~n~lsc~ping blocks, each of the blocks cnmpri.cing a top and a generally opposed bottom, first and generally opposed sides, each side extçn-ling from the top to the bottom, first and second generally opposed ends, each end extçn~ling from the top to the bottom and from the first side to the second side, and the 10 bottom comprising means for coupling the blocks with the anchoring means by receiving the ançhoring In accordance with another aspect of the invention, a plurality of landscaping blocks are provided, where each of the blocks comprised as a top and generally opposed bottom, first and second generally opposed sides, 15 each side çxtçntling from the top to the bottom, first and generally opposed ends, each end çxt~n-ling from the top to the bottom and from the first side to the second side, the bottom compri.~ing first and second generally opposed interior walls ext~n-ling from the bottom toward the top, ~lefining groove opening into the bottom and çxten-ling from the first to the second 20 end. Further, the blocks are placed end to end, the bottom of each block embedded in the substrate having an upper surface, the top of each block above the substrate upper surface, and the blocks defining an edging and the block grooves ~l~fining a con*nllous conduit.
In accordance with another aspect of the invention, a l~n~1ec~ping 25 system is provided having means for coupling landscaping blocks in an end to end relations_ip with a plurality of blocks, each of the blocks compri~in~;
WO 9S/32083 2 1 6 7 3 0 ~ PCT/US95tO6166 _ 9 _ a top and a generally opposed bottom, first and second generally opposed sides, each side exten-ling from the top to the bottom, first and second generally opposed ends, each end extçn-1ing from the top to the bottom and from the first side to the second side, the bottom comprising first and 5 second generally opposed interior walls exten~ling from the bottom toward the top ~lçfining a groove opening into the bottom and extçntling from the first side to the second side. The blocks are positioned end to end and embedded in a substrate, and adjacent ends of adjacent blocks are connected by coupling means ext~ntling into the grooves of the adjacent 10 blocks.
In accordance with another aspect of the invention, there is a method of molding a block comprising a top and a generally opposed bottom, first and second generally opposed sides, each side extending from the top to the bottom, first and second generally opposed ends, each end ext~on~ing from 15 the top to the bottom and from the first to the second side, wherein the first end defines an acute angle from the first side to the second side and the second end is generally perpendicular to the first and second sides. The method comprises the steps of positioning a platform in a mating position under a mold. The mold cnmpri~es a top, a bottom, and a continuous 20 vertical wall ext~nl1ing from the mold top to the mold bottom ~çfining a volume open at the top of the mold and further ~efining the cross-sectional shape of the block. The inner wall comprises a first pair of opposed side - walls defining the top and bottom of the block, and a second pair of opposed side walls ~lefining the first and second sides of the block. The 25 second pair of opposed side walls are angled at the top of the mold to define the first angled end of the block and the platform, positioned at the WO 9S/32083 ! PCT/US95/06166 216730~
bottom of the mold, defines the second end of the block. Additionally, the method includes introducing a block forming substance into the volume and colllp,~ssing the block forming substance in the volume from the top of the mold with a shoe having an angle that is complementary to the angled top 5 end of the second pair of opposed side walls of the mold. Additionally, the method includes the steps of moving the platform into a de-molding position away from the mold and removing the shoe to leave the molded block. The method may further include vibrating the mold and platform after introducing a block-forming substance into the volume. Further, the 10 mold may comprise a plurality of volumes.
In accordance with another aspect of the invention, there is a method of m~kin~ a first and second block, each block comprising a top and a generally opposed bottom, first and second generally opposed sides, each side extending from the top to the bottom, first and second generally 15 opposed ends, each end extending from the top to the bottom and from the first to the second side, wherein the first end defines an acute angle from the first side to the second side and the second end is generally perpendicular to the first and second sides. The method comprises the steps of positioning a platform in a mating position under a mold. The mold 20 comprises a top, a bottom, and a continuous vertical wall extending from the mold top to the mold bottom defining a volume open at the top of the mold and further defining a composite block having the cross-sectional shape of the first and second block position so that the top of the first block is parallel and connected to the top of the second block and the angled first 25 ends of the first and second blocks are at the top of the mold, wherein the inner wall comprises a first pair of opposed sidewalls ~lefining the bottom wo ss/32os3 - 11 2 1 6 7 3 0 ~ PCT/US95/06166 of the first block and bottom of the second block, and a second pair of opposed sidewalls defining the first and second sides of the f~rst and second blocks, the second pair of opposed sidewalls angled at the top of the mold to define the first angled end of the first and second blocks, and the platform at the bottom of the volume defining the second end of the first and second blocks. Additionally, the method includes introducing a block forming substance into the volume and co~llp~cssing the block-forming substance in the volume from the top of the mold with a shoe angled compl~ment~ly to the angled top end of the second pair of opposed sidewalls of the mold. Additionally, the method includes moving the platform into a de-molding position away from the mold and removing the shoe to leave the composite block. Additionally, the method may further inchlde splitting the composite block along the plane of the cormected tops of the first and second blocks forming the separate, disconnected first and second blocks. The method may further include vibrating the mold and platform. Further, the mold may comprise a plurality of volumes. Further, the block may be split by a splitting m~chine comprising a top splitting blade having a serrated lower edge. Further, the ~dj~cent blocks remain adjacent as a result of splitting the composite block.
DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of a landscaping block in accordance with the invention.
Figure 2a is an end view of a l~nd~c~ping block in accordance with the invention.
Figures 2b-2f are partial end views of ~lt~rn~te embotlimentc of a landscaping block in accordance with the invention.
WO9S/32083 ~ - 12 - PCT/US95106166 216730~
Figure 2g is an end view of a l~n-lsc~ring block inserted into a substrate in accordance with the invention.
Figures 3a-3c are end views of ~lt~ te embo~imçnt~ of a landscaping block showing the groove in accordance with the invention.
5Figure 3d is an end view of a l~n~lsc~ping block positioned over a pipe in accordance with the invention.
Figure 3e is an end view of a landscaping block positioned over electrical wiring in accordance with the invention.
Figure 4a is a perspective view of anchoring means in accordance 10withtheinvention.
Figure 4b is a perspective view of an alternate embodiment of anchoring means in accordance with the invention.
Figure 5a is a top view of a landscaping block in accordance with the invention.
lSFigure Sb is a top view of an alternate embodiment of a lan~cc~ring block in accordance with the invention.
Figure 5c is a top view of landscaping blocks aligned end to end to form a straight border in accordance with the invention.
Figure 5d is a top view of l~n(15c~ping blocks aligned end to end to 20form a curved border in accordance with the invention.
Figure 5e is a top view of landscaping blocks aligned end to end to form a curvilinear border in accordance with the invention.
Figure 6a is a perspective view of a l~ndsc~I)ing block system in accordance with the invention.
25Figure 6b is a perspective view of an ~ltern~te embodiment of a landscaping block system in accordance with the invention.
woss/320s3 2 1 6 73 0 5 PCT/US95/06166 Figure 6c is a perspective view of an ~ltçrn~*ve embodiment of a landscaping block system in accordance with the inven*on.
Figure 7 generally shows the steps of ...~ r~cturing the l~n~lsc~ping blocks of the present inven*on.
Figure 8 is a front view of a block molding m~chine.
Figure 9 is a perspec*ve view of an embodiment of the mold and platform of the present inven*on.
Figure lOa is a top view of an embodiment of the mold of the present invention.
Figure lOb is a top view of an ~ltçrn~te embodiment of the mold of the present inven*on.
Figure 11 is a sectional view of an embodiment of the mold along line x-x of the present inven*on.
Figure 12 is a perspective view of the compression head and shoe ~csembly of the present invention.
Figure 13 is a side view of the shoes of the present invention.
Figure 14 is a partial front view of the cut-offbar of the present invention.
Figure 15 is a front view of a splitter of the present invention.
Figure 16 is a top view of an alternate embodiment of the mold of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to Figures 1 - 6c there is shown a landscaping block 1 of the present invention. Block 1 is made of a rugged, weather-resist~nt m~teri~ crelably pre-cast concrete. Other suitable materials are plastic, reinforced fibers, wood, metal, and stone. As shown in Figure 1, block 1 WO 9S/32083 ~ - PCT/US95/06166 216730~
includes a top 2, a generally opposed bottom 3, and first and second generally opposed sides 4, 5, each side exten~ing from top 2 to bottom 3.
First and second generally opposed ends 6, 7 extend from top 2 to bottom 3 and from first side 6 to second side 7. Groove or channel 8 extends f-rom 5 bottom 3 into block 1 toward top 2, thereby having an opening at bottom 3, and ext~n(l~ from first end 6 to second end 7.
In a plcrellcd embodiment of the invention, block 1 extends a~pro,~;.,.~tely six inches from first end 6 to second end 7, four inches from top 2 to bottom 3, and four inches from first side 4 to second side 5 at lip 10 12. With these rlimen~ions, block 1 is light enough for relatively easy transport and placement, provides adequate separation height and width for edging, as well as providing a deep enough mower strip to reduce hand-l. ;.. ;-.g and allows for easy const~uction of a variety of straight and curved edging p~tt~rn.~. However, in order to meet the requirements of 15 dirre~cnl applicahons, block 1 may have larger or smaller limçn~ions and varymg proportlons.
As shown in Figure 2a, sides 4,5 each have an upper face 9 and a lower face 10. Upper face 9 is generally above-ground when the block is in use, providing the visual edging or separation. Lower face 10 is at and 20 below ground level and, in conjunction with groove 8, fixes block 1 in place in a substrate, typically dirt, sand, or other natural material.
Upper face 9 ext~n-ls from top 2 dowl,wald to inner edge 11 of lip 12. Face 9 may be planar and, in a prcfcllcd embo-lim~nt includes beveled edge 13 adjacent top 2. As shown in Figures 2b-2d, top 2 and face 9 may 25 have a variety of curved and/or textured shapes to meet the specific needs W O 95t32083 2 1 6 7 3 0 S P~rtUS95/06166 of any given application. Also, Figures 2e and 2f disclose alternate - embo-limçnt~ of block 1 with one or no lip 12.
Lip 12 defines a transition from upper face 9 to lower face 10.
Ledge 12 ext~ntls oulw~dly from upper face 9 to outer edge 14, at least 5 about one-fourth inch and ~efer~bly about five-eighths inch. As shown in Figure 2g, ledge 12 provides a mowing edge or strip that allows the wheels of a lawn mower to follow the conlou,~ of the block and allows the lawn mower to cut the grass adjacent the mowing strip, lessening the need for hand-l~ ng along the borders of a lawn.
In other applications of block 1, ledge 12: (1) provides an anchoring surface for placçrnent of l~n(lsc~pe rock, etc; (2) serves as a screed board leveling surface for paver in~t~ tions and provides interlock to prevent deterioration or loss of sub-base m~t~ri~ls when used as a paver curb or e~gin~ and (3) locks block 1 in place when used as an accent or passageway for conduit through a paved surface.
Fxt~n-ling dowllw~ud from outer edge 14 of ledge 12, lower face 10 has alignment strip 15 for easier placement of block 1 in the substrate and tapered portion 16 çxtentls to bottom edge 17. The adv~nt~ges of tapered portion 16 are discussed below.
As shown in Figure 1, groove or channel 8 extends into block 1 from bottom 3 toward top 2. In an embodiment shown in Figure 3a, groove 8 is defined by generally opposed interior walls 18a, 18b. The width of slot 8, - identifled by arrow D, is the distance between the opposed interior walls 18a, 18b and is wide enough to receive commonly available black plastic edging 19. As shown in Figures 4a and 4b, edging 19 may have various configurations. Typically, edging 19 have a lower bead or protrusion to WO 9S132083 - ~CI/US95/06166 allowing nailing or spiking in place. Figure 4a shows commonly available flexible black PVC edging or strip 20 having opposed vertical walls 21a, 21b, and a top 22 and a bottom 23 edge. As shown in Figure 4a, top edge 22 may include an elongated bead 24. As shown in Figure 4b, edging 19 5 may be a planar strip made of al----,;----"~ or other suitable material. F-l~ing 19 should be flexible to create the desired border shape and made of a suitable material for use in the desired substrate. Typically, edging 19 is partially embedded in a substrate by ~liggin~ a small trench, and also may be fixed in place by stakes.
Cavity 8 allows block 1 to fit over the top of and receive edging 19 or, as shown in Figure 3b, block 1 can be locked onto edging 20 by the key-hole cross-sectional configuration of slot 8. In the locking embodiment of Figure 3b, opposed interior walls 18a, 18b define an upper ~nn~ r receiving portion 25 for receiving the bead 24 of edging 20. Receiving 15 portion 25 has a lower opening that forms neck 26 which prevents bead 24 from moving downward out of upper receiving portion 25 without substantial force excee-ling the normal forces of the ~ulloullding substrate during freeze/thaw cycles. The lower portions of walls 18a, 18b preferably taper oulw~d or diverge towards sides 4, 5. Also, groove 8 can be tapered 20 from one end 6 to the other end 7, i.e., the slot width increases from one end 6 to the other end 7, for easier ~tt~çhment and det~.hment of block 1 to strip 20.
In the embodiment shown in Figure 3a, interior walls 18a, 18b are al)plo~ullately parallel, ~çfining a rect~n~ r region for receiving a planar 25 e~lging. In another embodiment shown in Figure 3c, interior walls define an WO 9Sr32083 2 1 6 7 ~ 0 5 PCT/US95/06166 upper curved shape at the top of groove 8 and a generally rect~n~ r cross-sectional shape ~ cent the bottom, accommodating a variety of edging~.
Groove or çh~nnel 8 accomplishes several goals. First, blocks 1 can be locked into place over exi~ting edging, which serves as an ~li nm~nt 5 guide, conce~ling the plastic or metal edging and providing an attractive, natural-looking edging Second, slot 8 provides connection, coupling, ~ligning, and anchoring means, ~ci~ting in the inst~ tion of the edging.
Finally, groove 8 allows for passage of pipe or other conduit for irrigation as shown in Figure 3d or electrical wiring as shown in Figure 3e along the edging In the embodiment of the invention shown in Figure 3b, tapered portion 15 of lower face 10 on sides 4, 5 and diverging interior walls 18a, 18b provide several advantages. First, this embodiment is more easily installed by allowing block 1 to be more easily inserted into the substrate or 15 soil than a flat bottomed surface. Second, this embodiment is more easily inserted over edging 19 and locked into place. Third, this embodiment is more resi~t~nt to frost heave than a flat bottomed surface, thereby ret~ ;..g its position in the substrate over a period of years. Finally, this embodiment allows block 1 to fit over pipes or conduits that would otherwise be too 20 wide.
The ends 6, 7 of block 1 provide another important aspect of the invention. In an embodiment of the invention shown in Figure 5a, end 6 is - angled a~l,roxi.. ~tçly 12 degrees from side 4 to side 5, while end 7 is ap~rox;.n~tely perpendicular to sides 4, 5. Figure 5b shows another 25 embodiment of block 1 having an angled end 6, but without lip 12. A
ple~,led range of angles is 10-18 degrees. As shown in Figures 5c - 5e, WO 95t32083 , `. ` PCT/US95/06166 216730~ 18-straight-end/angled-end block configurations allow for various straight (Figure 5c), curved (Figure 5d), curvilinear (Figure 5e) borders without having to cut the blocks at the installation site. At least nine diLrelenl shapes can be achieved using two blocks. In other embodiments, the blocks 5 may have both ends perpendicular to the sides, both ends angled from one side to the other, or ends with di~.~l-l angles. Plefelled angles are those divisible into 360 degrees (i.e. 9, 12, 15, 18 and 24 degrees) so that the blocks can make a circle to be used around a tree, for example.
There are numerous options for the appearance of top 2 and upper 10 face 9 of sides 4, 5. Any of these surfaces can have a natural or "split"
surface, smooth s~ ce, COldul-)y or other striated surface.
When block 1 is installed as shown in Figure 2e, block 1 is inserted into a substrate 40, which may be earth or other material. Lip 12, pler~lably planar, and iqlignment strip 15 assist in placing block 1 in a 15 ~le~llcd position wherein lip 12 is coplanar with the ~ulluu-lding substrate.Lip 12 provides a mowing or spacer strip that sep~les top 2 and sides 4, 5 from the substrate by the length of lip 12. Lip 12 may be on one or both sides of block 1 depending on the application.
A combination of blocks 1 can be used to create several l~n~l~c~ping 20 block systems. The first system is discussed above and shown schematically in Figure 6a. A new or existing edging 19 provides means for anchoring landscaping blocks 1 in a fixed position relative to the substrate 40. Anchoring means 19 is partially embedded in the substrate.
Using edging strip 20 disclosed in Figure 4a, bottom edge 23 is embedded 25 in the substrate and bead 24 is above the upper surface of the substrate.
The bottom groove or coupling means 8 at the bottom 3 of each block 1 is 2 1 6 7 3 0 r3 placed over and receives anchoring means 19 and the lower face 10 of each block 1 is also embedded in the substrate. The blocks 1 are aligned end to end along strip 19 thereby d~ning the l~n~1sc~ring border or e~ging Another system is to insert the blocks 1 in a substrate end to end 5 without using an edging 19, as shown in Figure 6b. Again, lower face 10 is embedded in the substrate and upper face 9 and top 2 define the edging above the substrate surface. Grooves 8 then form an interior conduit that can receive pipes, conduit, electrical wiring, or function alone as a drainage conduit.
Figure 6c discloses a third landscaping block system. The blocks 1 are inserted into substrate 40 end to end, thereby fixing the blocks 1 in the substrate. ~lignmçnt of the blocks is m~int~ined by use of connectors or coupling means 50 that connect the adjacent ends of the adjacent blocks.
For example, end 51 of block 60 is adjacent end 52 of block 61 and ends 51 15 and 52 are coupled by connector 50. The connectors can be tubing or a narrow strip that ~t~n~s from the upper portions of adjacent grooves.
Also, a single elongated tubing may pass through groove 8 from end to end the entire length of blocks.
The method of the present invention is shown generally in Figure 7.
20 First, the block-forming m~t~ri~l~7 typically water, cement, sand, and aggregate, are mixed and transported to a block molding m~hine. A wide variety of ~ lures are known to make blocks having various characteristics - such as strength, water absorbtion, density, shTink~ge, and other factors meeting ASTM standards and depending on the desired application of the 25 block. The ll~i~ e is l,lepared in any number of mixers known in the art.
The ll~i~lure is then placed in a hopper which transports the llli~ e to a 21673~c~
block molding m~hine shown generally in Figure 8. Any block molding m~c.hine known in the art`may be used. One m~chine found useful is the V3-12 Vibrapac, made by Besser Colllp~l~, Alpena, Michigan.
The llli~ e or fill is then poured or loaded into mold 70 sitting on 5 or mated with generally planar steel pallet 71 as shown in Figure 9.
Specific aspects of the mold are discussed further below. The top of mold 70 is then scraped with a cut-off bar to remove excess llli~lule. Mold 70 is then subjected to vertical compression by head 72 moving downward on top of mold 70. Further details of head 72 are provided below. Head 72 acts to 10 compress the fill within mold 70 for a period of time sufficient to form a solid, contiguous block. Generally, each block producing cycle has a duration of six to twelve seconds at a total load of 1500 to 2000 pounds.
Additionally, mold 70 and horizontal platform 71 may be agitated during compression.
Once the compression is complete, platform 71 is lowered vertically away from mold 70 into a de-molding or stripped position and head 72 pushes the newly molded blocks dowllwd~d through mold 70 so that they remain on platform 71. Head 72 is then raised vertically.
Once the blocks are formed, they are cured by various means known 20 in the art. Typically, blocks are cured in kilns for up to twenty-four hours under pressure and/or with steam. Once cured, the blocks may be split.
Splittin~ methods such as hand-splitting with h~mmer and chisel, and m~chine splitting are known in the art. Additional details of the splitter used in connection with the present invention are provided below. After 25 splitting, the blocks are palletized or otherwise packaged for .~hipment or storage.
wo ss/320s3 - 21 21 6 7 3 o ~ PCr/usg5/o6l66 The method of ~e present invention is more specifically directed to molding landscaping block 1, having angled first end 6. In order to more easily and efficiently make block 1, mold 70 and compression head 72 are used. A top view of an embodiment of mold 70 is shown in Figure lOa.
S Mold 70 has a front vertical wall 73, generally opposed back vertical wall 74, and generally opposed side walls 75a, 75b ~lefining a generally rect~n~ r, vertical outer wall or edge 76. Mold 70 further includes one or more volumes 77 extending from the top 78 to the bottom 79 of mold 70.
Volume 77 is defined by a continuous vertical wall 80, described further lO below. When mold 70 is placed on top of or mated with platform 71, volume 77 is open at the top 78 of mold 70, but closed at the bottom 79 of the mold by platform 71.
As shown in Figures 9 and lOa, block 1 is preferably molded vertically, i.e., the end 6 to end 7 dimension of block 1 is positioned 15 vertically in mold 70 from top 78 to bottom 79. Vertical wall 80, which delimits volume 77, defines the cross-sectional shape of block 1. Vertical wall 80 includes a first pair of opposed sidewalls 8 la, 8 lb and second pair of opposed sidewalls 82a, 82b.
Also as shown in Figure lOa, block 1 is ~lerelably formed in pairs.
20 For example, volume 83 in Figure lOa defines a composite block 84 which comprises a first block 85 and second block 86 pair. Vertical wall 80 is configured so that blocks 85, 86 are positioned top to top, i.e., top 2 of - block 85 is parallel and connected to top 2 of block 86 at plane 89. As will be discussed further below, composite block 84 is split along plane 89 to 25 form first block 85 and second block 86, each having a natural or split surface ~ea~ ce at top 2. The first pair of opposed sidewalls 81a, 81b WO 9S/32083 ~ - 22 - PCI/US95/06166 2167~
define bottom 3 of block 85 and bottom 3 of block 86, respectively. The second pair of opposed sidewalls 82a, 82b define sides 4, 5 of block 85 and sides 4, 5 of block 86.
When mold 70 is positioned in the molding position on platform 71, S the second end 7 of blocks 85, 86, respectively, is defined by platform 71.
The first angled end 6 of blocks 85, 86 are formed at the top 78 of mold 70.
As shown in the front view of mold 70, Figure 11, the top 78 of mold 70 has a saw-tooth or serrated shape. The angle of each side 100, 101 of top 99 defines the angle of the first end of each block 77 in the four respective 10 rows 99 of mold 70.
In one embo~limçnt mold 70 is formed by a solid block of steel, for example, with volume 77 m~hined out of the solid block.
In order to form angled end 6 on blocks 85, 86 in mold 70, co~ ression means 72 includes a plurality of shoes 110, with each shoe 110 fitting over the top of each volume 77 to form angled end 6. The general head 72 and shoe 110 configuration is shown in Figure 13.
As shown in Figure 14, the bottom 81 of each shoe 110 has an angle complementary to the desired angle of first end 6 of each molded block 1.
Therefore, when head 72 is compressed downward into mold 70 and each 20 shoe 110 co~ lesses into each volume 77, there is equal pressure across angled end 6, thereby forming a structurally sound angled end 6 on block 1.
As discussed above, block m~chines may include a cut-off bar to scrape excess concrete offthe top 78 of mold 70 and bottom of shoes 110.
As shown in Figure 15, one embo~1iment of cut-offbar 111 has a serrated 25 bottom edge 113 with angles complçmçnt~ry to the top 78 of mold 70. In another embo~imçnt cut-offbar 111 is generally rect~n~ r with planar WO 9S/32083 2 1 6 7 ~ Q 5 rcT/usgs/06l66 top and bottom edges. In use, this embodiment would move up and down following the collloul~ of the top 78 of mold 70 and shoes 110. In another embo-limçnt cut-off bar 111 may have flexible top and bottom edges.
In an ~ltern~te embo-liment volumes 77 in mold 70 are rotated 5 ninety degrees, as shown in Figure 10b. The angles on shoes 110 are also rotated ninety degrees to retain the same angled ends 6 on block 1. Cut-off bar 111 would then be generally rect~n~ r and move vertically as it passes over the top 78 of mold 70 to perform its scraping function.
Once composite block 84 is formed using mold 70 and head 72 10 described above, it is cured. After curing, block 84 is split. Figure 16 generally shows a splitter 115 that can be used with the present invention.
A top blade 116 and bottom blade 117 are used to split block 84 along the desired plane 89.
Since composite block 84 is molded having a top angled end, top lS blade 116 is serrated with angles that are complement~ry to the angled end of composite block 84. Since the bottom of composite block 84 is flat, bottom blade 117 is straight. When composite block 84 is positioned in splitter l lS so that blades 116 and 117 are co-planar with plane 89, bottom blade 117 is forced upward and top blade 116 is forced downward, thereby 20 applying generally equal pressure along plane 89 to split block 84 into blocks 85 and 86.
Additionally, as shown in Figure 10, sidewalls 82a, 82b may include v-shaped grooves 130a, 130b, respectively, that assists in providing a clean split along plane 89. Further, a v-shaped groove 131 can be provided at the 25 end of composite block 84 rlçfining ends 6 of blocks 85 and 86 to assist in providing a straight split at plane 89. Mold 70 in Figure 10a is configured WO 9S132083 ~ PCIIUS95/06166 21673~
so that when composite block 84 is split into separate blocks, the splitting process does not force adjacent blocks away from each other, thereby requiring additional h~ntlling or processing of the blocks. Referring to Figure lOa, when the first line of composite blocks, id~ntified as blocks A
S through D, are split, the angled end 6 on blocks A and D slopes downward toward walls 75a and 75b respectively. Therefore, blocks A and D do not fall away from blocks B and C.
In the embodiment of mold 70 shown in Figures 9 and 10, twelve pairs of blocks 1 are formed with each pair having a block 1 with an angled 10 end 6 complementary to the angled end 6 ofthe other block 1 of the pair, yielding twenty-four blocks per cycle. In a typical set-up, six to ten molding cycles may be completed per minute.
Mold 70 need not form block 1 in pairs. Figure 17 shows an ~ltern~te mold 120 where each volume 121 defines the cross-sectional 15 shape of a single block 1. In this embodiment splitter 115 is not required.
The above discussion provides various examples and embodiments of the invention and are not intended to limit the scope of the invention.
Claims (8)
1. A method of molding a block comprising a top and a generally opposed bottom, first and second generally opposed sides, each side extending from the top to the bottom, first and second generally opposed ends, each end extending from the top to the bottom and from the first side to the second side, wherein the first end defines an acute angle from the first side to the second side, and the second end is generally perpendicular to the first and second sides, the method comprising the steps of:
(a) positioning a platform in a mating position under a mold, the mold comprising a top, a bottom, a continuous vertical wall extending from the mold top to the mold bottom defining a volume open at the top of the mold and further defining the cross-sectional shape of the block, wherein the inner wall comprises a first pair of opposed sidewalls defining the top and bottom of the block, and a second pair of opposed sidewalls defining the first and second sides of the block, the second pair of opposed sidewalls angled at the top of the mold to define the first angled end of the block, and the platform, positioned at the bottom of the mold, defining the second end of the block;
(b) introducing a block-forming substance into the volume;
(c) compressing the block-forming substance in the volume from the top of the mold with a shoe having an angle that is complementary to the angled top end of the second pair of opposed sidewalls of the mold;
(d) moving the platform into a demolding position away from the mold; and (e) removing the shoe to leave the molded block.
(a) positioning a platform in a mating position under a mold, the mold comprising a top, a bottom, a continuous vertical wall extending from the mold top to the mold bottom defining a volume open at the top of the mold and further defining the cross-sectional shape of the block, wherein the inner wall comprises a first pair of opposed sidewalls defining the top and bottom of the block, and a second pair of opposed sidewalls defining the first and second sides of the block, the second pair of opposed sidewalls angled at the top of the mold to define the first angled end of the block, and the platform, positioned at the bottom of the mold, defining the second end of the block;
(b) introducing a block-forming substance into the volume;
(c) compressing the block-forming substance in the volume from the top of the mold with a shoe having an angle that is complementary to the angled top end of the second pair of opposed sidewalls of the mold;
(d) moving the platform into a demolding position away from the mold; and (e) removing the shoe to leave the molded block.
2. The method of claim 1, further comprising:
(f) vibrating the mold and platform.
(f) vibrating the mold and platform.
3. The method of claim 1, wherein the mold comprises a plurality of volumes.
4. A method of making a first and second block, each block comprising a top and a generally opposed bottom, first and second generally opposed sides, each side extending from the top to the bottom, first and second generally opposed ends, each end extending from the top to the bottom and from the first side to the second side, wherein the first end defines an acute angle from the first side to the second side, and the second end is generally perpendicular to the first and second sides, the method comprising:
(a) positioning a platform in a mating position under a mold, the mold comprising a top, a bottom, a continuous vertical wall extending from the mold top to the mold bottom defining a volume open at the top of the mold and further defining a composite block having the cross-sectional shape of the first and second block positioned so that the top of the first block is parallel and connected to the top of the second block and the angled first ends of the first and second blocks are at the top of the mold, wherein the inner wall comprises a first pair of opposed sidewalls defining the bottom of the first block and bottom of the second block, and a second pair of opposed sidewalls defining the first and second sides of the first and second blocks, the second pair of opposed sidewalls angled at the top of the mold to define the first angled end of the first and second blocks, and the platform at the bottom of the volume defining the second end of the first and second blocks;
(b) introducing a block-forming substance into the volume;
(c) compressing the block-forming substance in the volume from the top of the mold with a shoe angled complementary to the angled top end of the second pair of opposed sidewalls of the mold;
(d) moving the platform into a demolding position away from the mold;
(e) removing the shoe to leave the composite block; and (f) splitting the composite block along the plane of the connected tops of the first and second blocks forming the separate, disconnected first and second blocks.
(a) positioning a platform in a mating position under a mold, the mold comprising a top, a bottom, a continuous vertical wall extending from the mold top to the mold bottom defining a volume open at the top of the mold and further defining a composite block having the cross-sectional shape of the first and second block positioned so that the top of the first block is parallel and connected to the top of the second block and the angled first ends of the first and second blocks are at the top of the mold, wherein the inner wall comprises a first pair of opposed sidewalls defining the bottom of the first block and bottom of the second block, and a second pair of opposed sidewalls defining the first and second sides of the first and second blocks, the second pair of opposed sidewalls angled at the top of the mold to define the first angled end of the first and second blocks, and the platform at the bottom of the volume defining the second end of the first and second blocks;
(b) introducing a block-forming substance into the volume;
(c) compressing the block-forming substance in the volume from the top of the mold with a shoe angled complementary to the angled top end of the second pair of opposed sidewalls of the mold;
(d) moving the platform into a demolding position away from the mold;
(e) removing the shoe to leave the composite block; and (f) splitting the composite block along the plane of the connected tops of the first and second blocks forming the separate, disconnected first and second blocks.
5. The method of claim 4, further comprising (g) vibrating the mold and platform.
6. The method of claim 4, wherein the mold comprises a plurality of volumes.
7. The method of claim 4, wherein the composite block is split by a splitting machine comprising a top splitting blade having a serrated lower edge.
8. The method of claim 4, wherein adjacent blocks remain adjacent as a result of splitting the composite block.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US24600494A | 1994-05-19 | 1994-05-19 | |
| US08/246,004 | 1994-05-19 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2167305A1 true CA2167305A1 (en) | 1995-11-30 |
Family
ID=22928958
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2167305 Abandoned CA2167305A1 (en) | 1994-05-19 | 1995-05-19 | Method of manufacturing a block |
Country Status (4)
| Country | Link |
|---|---|
| AU (1) | AU680146B2 (en) |
| CA (1) | CA2167305A1 (en) |
| NZ (1) | NZ287257A (en) |
| WO (1) | WO1995032083A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA2492250C (en) | 2005-01-11 | 2013-10-08 | Novabrik International Inc. | A molding equipment and method to manufacture stackable inter-engaging bricks, blocks, stones and the like with a smooth or embossed face |
Family Cites Families (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2957278A (en) * | 1956-07-05 | 1960-10-25 | Nat Concrete Masonry Ass | Masonry construction systems |
| US4335549A (en) * | 1980-12-01 | 1982-06-22 | Designer Blocks, Inc. | Method, building structure and side-split block therefore |
| CA1222149A (en) * | 1984-07-19 | 1987-05-26 | Rodney J.P. Dietrich | Self-leveling block and method of use |
| NL8502484A (en) * | 1985-08-23 | 1987-03-16 | Rook Beheer Bv | METHOD AND APPARATUS FOR MANUFACTURING STONES IN A MOLD |
| US4738059A (en) * | 1986-01-31 | 1988-04-19 | Designer Blocks, Inc. | Split masonry block, block wall construction, and method therefor |
| CA1298982C (en) * | 1988-02-25 | 1992-04-21 | Eugene M. Bender | Retaining wall construction and blocks therefore |
| US4920712A (en) * | 1989-01-31 | 1990-05-01 | Stonewall Landscape Systems, Inc. | Concrete retaining wall block, retaining wall and method of construction therefore |
| CA1309611C (en) * | 1989-07-13 | 1992-11-03 | Bertin Castonguay | Precast curb system |
| US5294216A (en) * | 1989-09-28 | 1994-03-15 | Anchor Wall Systems, Inc. | Composite masonry block |
| US5062610A (en) * | 1989-09-28 | 1991-11-05 | Block Systems Inc. | Composite masonry block mold for use in block molding machines |
| US5017049A (en) * | 1990-03-15 | 1991-05-21 | Block Systems Inc. | Composite masonry block |
| US5217630A (en) * | 1990-05-31 | 1993-06-08 | Sayles Jerome D | Apparatus for forming an irregular surface block |
| US5249950B1 (en) * | 1992-01-30 | 1997-05-13 | Anchor Wall Syst | Heated stripper shoe assembly |
-
1995
- 1995-05-19 WO PCT/US1995/006166 patent/WO1995032083A1/en active Application Filing
- 1995-05-19 NZ NZ28725795A patent/NZ287257A/en unknown
- 1995-05-19 CA CA 2167305 patent/CA2167305A1/en not_active Abandoned
- 1995-05-19 AU AU25916/95A patent/AU680146B2/en not_active Ceased
Also Published As
| Publication number | Publication date |
|---|---|
| AU680146B2 (en) | 1997-07-17 |
| NZ287257A (en) | 1996-12-20 |
| WO1995032083A1 (en) | 1995-11-30 |
| AU2591695A (en) | 1995-12-18 |
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