JP2008537512A - Mason reblock and method for creating a mason reblock with overlapping faces - Google Patents

Abstract

A mason reblock molded by a mason reblock machine using a mold assembly, the mold assembly having a plurality of liner plates, at least one of the plurality of liner plates being movable; The masonry block includes a first lateral surface, a second lateral surface facing the first lateral surface, a first main surface joining the first lateral surface to the second lateral surface, A second main surface opposite to the main surface of the first main surface, the second main surface joining the first lateral surface to the second lateral surface, and joining the first main surface to the second main surface. A first end face, and a second end face facing the first end face and joining the first main face to the second main face, the first end face being a non-planar end face of a similar masonry block And a non-planar end surface configured to overlap with the negative surface of the non-planar surface Through operation of the movable liner plates having, formed during the molding process, masonry block.

Description

(Citation of related application)
The subject matter of this application is related to the subject matter of US Provisional Patent Application No. 60 / 644,106 (filed January 13, 2005), and the priority for that application is 35 U.S. Pat. S. C. Claimed under section 119 (e), which is hereby incorporated by reference.

(Technical field)
The present invention relates generally to masonry blocks, and more particularly to a method of creating a masonry block having at least one non-plane configured to overlap the non-plane of a masonry block and similar masonry blocks. .

  Concrete blocks, also called concrete masonry units, are used to build numerous structures. Examples of concrete masonry units include blocks with hollow cores, commonly referred to as “gray” blocks, pavement blocks, and retaining wall blocks. Gray blocks are typically used in the construction of commercial and public buildings, and even in the construction of family homes. Retaining wall blocks are used to build numerous landscaping structures, such as raised flower beds and soil retaining walls.

  These blocks are generally rectangular in shape, and when they are stacked and stacked to form a wall or other structure, a brick-like pattern that is familiar to everyone is formed by connecting lines between adjacent blocks. The FIG. 20A is an illustrative example of a portion of a wall structure 880 that is constructed using a conventional gray block 890 (see FIG. 20B) and has a familiar brick-like pattern. Yes. In many cases it is not a problem, but when trying to build a structure with a natural appearance, for example, a building using textured gray blocks (sometimes called building units) Or when building other landscaping structures that use soil retaining walls or retaining wall blocks formed with a rock or stone-like appearance, such a brick-like pattern is Not desirable.

  One embodiment of the present invention provides a mason reblock molded by a mason reblock machine, wherein the mason reblock machine uses a mold assembly having a plurality of liner plates, at least one of the plates being The masonry block includes a first lateral surface, a second lateral surface opposite to the first lateral surface, and a first main surface joining the first lateral surface to the second lateral surface. A first main surface facing the first main surface, the second main surface facing the first main surface and joining the first lateral surface to the second lateral surface, and the first main surface joining the second main surface And a second end surface facing the first end surface and joining the first main surface to the second main surface, the first end surface being a non-planar end surface of a similar masonry block Non-planar end face with non-planar configured to fit and overlap with, during the molding process Formed by the action of the movable liner plates having negative.

  In the following detailed description, reference is made to the accompanying drawings, which are a part of this specification and are shown by way of illustration of specific embodiments in which the invention may be practiced. In this regard, for the orientation of the described figures, terms indicating the direction are used, such as “top”, “bottom”, “front”, “back”, “leading”, “trailing”, etc. . Because components of embodiments of the present invention can be arranged in a variety of different directions, the terminology terms are used for illustration purposes and are in no way limiting. It should be understood that other embodiments may be used and structural or logical changes may be made without departing from the scope of the invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.

  As described herein and illustrated by FIGS. 21-34D, at least one non-planar end face configured to fit and overlap with a masonry block and an end face of a similar masonry block. And a method for creating a masonry block having: Examples of mold and drive assemblies suitably configured for use with the present invention are shown in FIGS. 1-19 and with US patent application Ser. No. 10 / 629,460 (filed Jul. 29, 2003). U.S. Patent Application No. 10 / 879,381 (filed June 29, 2004) and U.S. Patent Application No. 11 / 036,147 (January 13, 2005), which are described and illustrated below, Each of the applications is assigned to the same successor as the present invention and is incorporated herein by reference.

  FIG. 1 is a perspective view of one exemplary embodiment of a mold assembly 30 having moveable liner plates 32a, b32, 33c, and 33d in accordance with the present invention. The mold assembly 30 includes a drive system assembly 31, which has side members 34a, 34b and cross members 36a, 36b, the side members and cross members respectively being inner walls 38a, 38b, 40a, and 40b and bonded together, the inner surface forms a mold box 42. In the illustrated embodiment, the cross members 36 a and 36 b are bolted to the side members 34 a and 34 b using bolts 37.

  Movable liner plates 32a, 32b, 32c, and 32d have front surfaces 44a, 44b, 44c, and 44d, respectively, and are configured to form a mold cavity 46. In the illustrated embodiment, each liner plate has an associated gear drive assembly disposed inside an adjacent mold frame member. A portion of the gear drive assembly 50 corresponding to the liner plate 32a and disposed inside the cross member 36a is shown extending through the side member 34a. Each gear drive assembly is optionally directed to the inside of the mold cavity 46 by applying a first force in a first direction coupled to the associated liner plate and parallel to the associated cross member. The liner plate is moved away from the inside of the mold cavity 46 by moving the liner plate and applying a second force in a direction opposite to the first direction. Each of the side members 34a, 34b and the cross members 36a, 36b has a corresponding lubricating oil port that extends into the member and provides lubricating oil to the corresponding gear element. For example, lubricating oil ports 48a and 48b. The gear drive assembly and movable liner plate according to the present invention are discussed in further detail below.

  In operation, the mold assembly 30 is optionally coupled to a concrete block machine. However, for ease of illustration, the concrete block is not shown in FIG. In one embodiment, the mold assembly 30 is installed in the concrete block machine by bolting the side members 34a and 34b of the drive system assembly 31 to the concrete block machine. In one embodiment, the mold assembly 30 further includes a head shoe assembly 52 having dimensions that are substantially equal to the dimensions of the mold cavity 46. Head shoe assembly 52 is also configured to be selectively coupled to a concrete block machine.

  First, the liner plates 32 a to 32 d extend by a desired distance toward the inside of the mold box 42 to form a desired mold cavity 46. Next, the shake table on which the pallet 56 is placed is lifted up and the pallet 56 contacts to form the bottom of the mold cavity 46. In one embodiment, a core bar assembly (not shown) is placed in the mold cavity 46 to create a space in the finished block according to the design needs of the particular block.

  The mold cavity 46 is then filled with concrete from a movable feed box drawer. The head shoe assembly 52 is lowered onto the mold 46 (as indicated by the directional arrows 54) and presses the concrete with hydraulic or mechanical force. The head shoe assembly 52, together with the vibration table, simultaneously vibrates the mold assembly 30, and the compressive force of the concrete in the mold cavity 46 becomes very high. A high level of compression force fills every space in the mold and quickly reaches a level of hardness that allows the completed block to be immediately removed from the mold cavity 46.

  The completed block is first removed by contracting the liner plates 32a-32d. Next, the head shoe assembly 52 and shaking table are lowered down with the pallet 56 (in the direction opposite to the direction indicated by arrow 58), but the mold assembly 30 remains intact and the head shoe assembly 56 is The completed block is pushed out of the mold cavity 46 and placed on the pallet 52. When the lower edge of the head shoe assembly 52 falls below the lower edge of the mold assembly 30, the conveyor system moves the pallet 56, carries away the completed block, and a new pallet is placed. The above process is repeated to create additional blocks.

  By shrinking the liner plates 32a-32d prior to removal of the completed block from the mold cavity 46, the liner plates 32a-32d are not worn much and thus increase the operational life. In addition, the moveable liner plates 32a-32d also allow the concrete blocks to be molded in a vertical position relative to the pallet 56 instead of the standard horizontal position, so that the head shoe assembly 52 is finished concrete. Contact with the “face” of the block. A “face” is the surface of a block, which may be exposed for ornamental purposes after being installed on a wall or other structure.

  FIG. 2 is a perspective view 70 showing a movable liner plate and corresponding gear drive assembly, eg, movable liner plate 32a and corresponding gear drive assembly 50, in accordance with the present invention. For the purposes of illustration, the side members 34a and cross members 36 are not shown. The gear drive assembly 50 optionally includes a first gear element 72 coupled to the liner plate 32 a, a second gear element 74, and a single gear coupled to the second gear element 74 via a piston rod 78. One rod end double acting air cylinder (cylinder) 76 and a gear track 80 are included. The cylinder 76 includes an opening 82 for receiving a pneumatic fitting. In one embodiment, the cylinder 76 comprises a hydraulic cylinder. In one embodiment, the cylinder 76 comprises a double rod end double acting cylinder. In one embodiment, the piston rod 78 is threadably coupled to the second gear element 74.

  In the embodiment of FIG. 2, a first gear element 72 and a second gear element 74 are shown and are referred to below as a gear plate 72 and a second gear element 74, respectively. However, although illustrated as gear plates and cylindrical gear heads, the first gear element 72 and the second gear element 74 can be any suitable shape and size.

  The gear plate 72 includes a plurality of angled channels on the first major surface 84 and is configured to slide on the gear track 80. The gear track 80 is slidably inserted into a gear slot (not shown) extending from the inner wall 40a into the cross member 36a. The cylindrical gear head 74 includes a plurality of angled channels on a surface 86 adjacent to the first major surface 84 of the female gear plate 72, the angled channels being the radius of the cylindrical gear head 74. And is configured to slidably engage and mate with the angled channel of the gear plate 72. Liner plate 32a includes guide posts 88a, 88b, 88c, and 88d extending from back surface 90. Each guide post is configured to be slidably inserted into a corresponding guide hole (not shown) extending from the inner wall 40a into the cross member 36a. Gear slots and guide holes are discussed in detail below.

  When the cylinder 76 extends the piston rod 78, the cylindrical gear head 74 moves in the direction indicated by the arrow 92, and the gear plate 72 and the liner plate 32a are Move toward the inside of the mold 46 as indicated by 94. Note that, as shown, FIG. 2 depicts the piston rod 78 and the cylindrical gear head 74 in the extended position. When the cylinder 76 contracts the piston rod 78, the cylindrical gear head 74 moves in the direction indicated by arrow 96, and the gear plate 72 and liner plate 32 are moved from the inside of the mold as indicated by arrow 98. Move away. As the liner plate 32a moves toward or away from the center of the mold, the gear plate 72 slides in the guide track 80 and the guide posts 88a-88d slide in the corresponding guide holes. .

  In one embodiment, removable liner face 100 is optionally coupled to surface 44a via fasteners 102a, 102b, 102c, and 102d extending from liner plate 32a. The removable liner face 100 is configured to provide a desired shape and / or to provide a desired engraved pattern containing text on blocks created in the mold 46. In this regard, the removable liner face 100 includes a negative of the desired shape or pattern. In one embodiment, removable liner face 100 comprises a polyurethane material. In one embodiment, removable liner face 100 comprises a rubber material. In one embodiment, the removable liner plate comprises a metal or metal alloy, such as iron or aluminum. In one embodiment, the liner plate 32 further includes a heater installed in the recess 104 on the back surface 90, which helps to harden the concrete in the mold 46, and the surface 44a and the removable liner face 100. To reduce the adhesion of concrete.

  FIG. 3A is a top view 120 of the gear drive assembly 50 and liner plate 32a, as indicated by the directional arrows 106 in FIG. In the figure, the side members 34a, 34b and the cross member 36a are indicated by broken lines. The guide posts 88c and 88d are slidably inserted into the guide holes 122c and 122d, respectively, and the guide holes extend from the inner surface 40a to the cross member 36a. Although guide holes 122a and 122b corresponding to the guide posts 88a and 88b are not shown, they are arranged side by side under the guide holes 122c and 122d. In one embodiment, guide hole bushings 124c and 124d are inserted into guide holes 122c and 122d, respectively, and slidably receive guide posts 88c and 88d, respectively. The guide hole bushings 124a and 124b are not shown, but are arranged side by side under the guide hole bushings 124c and 124d. The gear track 80 is shown slidably inserted into the gear slot 126, which extends through the cross member 36 a having a gear plate 72 that slides within the gear track 80. The gear plate 72 is shown as being coupled to the liner plate 32a by a plurality of fasteners 128 that extend from the surface 44a through the liner plate 32a.

  The cylindrical gear shaft extends through the side member 34 a and extends into the intersection 36 a and is indicated by a dashed line 134 so as to at least partially intersect the gear slot 126. The cylindrical gear head 74, the cylinder 76, and the piston rod 78 are slidably inserted into the gear shaft 134, and the cylindrical gear head 74 is positioned beyond the gear plate 72. The angled channel of the cylindrical gear head 74 is shown as a dashed line 130 and meshes with the angled channel of the gear plate 72 as indicated at 132.

  FIG. 3B is a side view 140 of the gear drive assembly 50 and liner plate 32a, as indicated by the directional arrow 108 in FIG. The liner plate 32a is shown at least partially extending from the cross member 36a. Similarly, guide posts 88a and 88d are shown partially extending from guide hole bushings 124a and 124d, respectively. In one embodiment, a pair of limiting rings 142a and 142d are selectively coupled to the guide posts 88a and 88, respectively, to limit the extension distance that the liner plate 32a can extend from the cross member 36a toward the inside of the mold cavity 46. To do. The limiting rings 142b and 142c corresponding to the guide posts 88b and 88c, respectively, are not shown, but are arranged behind the limiting rings 142a and 142d. In the illustrated embodiment, the limiting ring is shown to be located substantially at the end of the guide post, thereby allowing a substantially maximum extension distance from the cross member 36a. However, the limiting ring can be placed at other locations along the guide post, thereby adjusting the allowable extension distance.

  4A and 4B are top views 150 and 160 of the mold assembly 30, respectively. FIG. 4A illustrates liner plates 32a, 32b, 32c, and 32d in a contracted position. Liner faces 152, 154, and 154 correspond to liner plates 32b, 32c, and 32d, respectively. FIG. 4B illustrates liner plates 32a, 32b, 32c, 32d and their corresponding liner faces 100, 152, 154, 156 in the extended position.

  FIG. 5A is a top view 170 of the gear plate 72. The gear plate 72 includes a plurality of angled channels 172 running across the upper surface 174 of the gear plate 72. The angled channel 172 forms a plurality of corresponding linear “teeth” 176 that have a top surface 174 as a surface. Each angled channel 172 and each tooth 176 has a width 178 and 180, respectively. The angled channel runs across the gear plate 72 at an angle (Θ) 182 from 0 ° indicated at 186.

  FIG. 5B is an end view (“A”) 185 of the gear plate 72, as indicated by the directional arrows 184 in FIG. ing. Each angled channel has a depth 192.

  FIG. 5C illustrates a view 200 of the flat surface 202 of the cylindrical gear head 76. The cylindrical gearhead 76 includes a plurality of angled channels 204 that run across the surface 202. The angled channel 204 forms a plurality of corresponding linear teeth 206. The angled channel 204 and the linear teeth 206 have widths 180 and 178, respectively, the width of the linear teeth 206 substantially matches the width of the angled channel 172, and the angled channels The width of 204 substantially matches the width of the linear teeth 176. Angled channel 204 and teeth 206 run across surface 202 at an angle (Θ) 182 from 0 ° indicated at 186.

  FIG. 5D is an end view 210 of the cylindrical gear head 76, as indicated by the directional arrows 208 in FIG. 5C, further illustrating the plurality of angled channels 204 and liner teeth 206. The surface 202 is a flat surface and is in a direction perpendicular to the radius of the cylindrical gear head 76. Each angled channel has a depth 192 from the flat surface 202.

  When the cylindrical gear head 76 is "rotated" and positioned across the surface 174 of the gear plate 72, the liner teeth 206 of the gear head 76 mesh with the angled channel 172 of the gear plate 72, and In combination, the liner teeth 176 of the gear plate 72 engage and mate with the angled channel 204 of the gear head 76 (see also FIG. 2). When the gear head 76 is forced to move in the direction 92, the liner teeth 206 of the gear head 76 push the liner teeth 176 of the gear plate 72, forcing the gear plate 72 to move in the direction 94. Conversely, when the gear head 76 is forced to move in the direction 96, the liner teeth 206 of the gear head 76 push the liner teeth 176 of the gear plate 72, causing the gear plate 72 to move in the direction 98. Forcing.

  In order for the cylindrical gear head 76 to force the gear plate 72 to move in directions 94 and 98, the angle (Θ) 182 must be greater than 0 ° and less than 90 °. However, Θ 182 preferably exceeds at least 45 °. When Θ 182 is 45 ° or less, the cylindrical gear head 74 moving in the direction 92 presses the gear plate 72 in the direction 94 when the concrete in the mold 46 is compressed. Thus, the gear plate 72 is forced to move in the direction 98 and requires more force than to push the cylindrical gear head 74 in the direction 96. The more Θ 182 exceeds 45 ° and the greater the angle, the greater the force required on the gear plate 72 in the direction 98 to move the cylindrical gear head 74 in the direction 96. In fact, at an angle of 90 °, regardless of how much force is applied to the gear plate 72 in the direction 98, the gear plate 72 has a cylindrical gear head in either direction 92 or 96. It is impossible to move. Indeed, the angle (Θ) acts as a multiplier for the force provided to the cylindrical gear head 74 by the cylinder 76 via the piston rod 78. The amount of force required to be applied to the gear plate 72 in the direction 98 to move the cylindrical gear head 74 in the direction 96 when Θ 182 is greater than 45 ° causes the gear plate 72 to Necessary to be applied to the cylindrical gear head 74 in the direction 92 through the piston rod 78 in order to “hold” in place (ie when the concrete is compressed in the mold 46). It is larger than the magnitude of the force.

  However, when the cylindrical gear head 74 is forced to move in direction 92, the greater Θ 182 exceeds 45 ° and the greater the angle, the more gear plate 72 and thus the corresponding liner plate 32a is in direction 94. The distance traveled is small. A preferred operating angle for Θ 182 is about 70 °. This angle is required to be applied in the direction 98 on the gear plate 72 in order to force the gear head 74 to move towards the direction 96, in general equilibrium, ie the distance traveled by the gear plate 72. It is a compromise between an increase in the level of power. When concrete is compressed in mold 46, gear plate 72 and cylindrical gear head 74 and their corresponding angled channels 176 and 206 are required to maintain the position of liner plate 32a. Reducing the required psi rate of the cylinder 76 and reducing the wear provided by the cylinder 76. Further from the above description, it is clear that one way to control the travel distance of the liner plate 32a is to angle the Θ 182 of the angled channel 176 of the gear plate 72 and the cylindrical gear head 74. Controlling the angle of Θ 182 of channel 206 respectively.

  FIG. 6A is a top view 200 of the gear track 80. The gear track 80 has an upper surface 220, a first end surface 224, and a second end surface 226. The rectangular gear channel is indicated by dashed line 228 and has a first opening 230 and a second opening 232 and extends through gear track 80. The arcuate channel 234 has a radius required to accommodate the cylindrical gearhead 76, extends across the top surface 220, passes through the top surface 222, and extends through the gear channel 228 to a gear window 236. Form. The gear track 80 has a width 238 that is slightly less than the gear opening 126 in the side member 36a (see also FIG. 3A).

  6B is an end view 250 of the gear track 80, as indicated by the directional arrows 240 in FIG. 6A, further illustrating the gear channel 228 and the arcuate channel 234. FIG. The gear track 80 has a depth 252 that is slightly less than the height of the gear opening 126 in the side member 36a (see FIG. 3A). FIG. 6B is a side view 260 of the gear track 80, as indicated by the arrow 242 indicating the direction of FIG. 6A.

  FIG. 7 is a top view 270 illustrating the relationship between the gear track 80 and the gear plate 72. The gear plate 72 has a width 272 that is slightly less than the width 274 of the gear track 80, and the gear plate 72 can be slidably inserted into the gear channel 228 through the first opening 230. When the gear plate 72 is inserted into the gear track 80, the angled channels 172 and the linear teeth 176 are exposed through the gear window 236.

  FIG. 8A is a top view 280 illustrating the relationship between the gear plate 72, the cylindrical gear head 74, and the gear track 80. Gear plate 72 is shown as being slidably inserted into guide track 80. The cylindrical gear head 74 is shown as being disposed within the arcuate channel 234, and the angled channel and linear teeth of the cylindrical gear head 74 are connected to the angled channel 172 of the gear plate 72. And slidably meshed with and combined with the linear teeth 176. When the cylindrical gear head 74 is moved in the direction 92 by extending the piston rod 78, the gear plate 72 extends outward from the gear track 80 in the direction 94 (also see FIG. 9B below). reference). When the cylindrical gear head 74 is moved in the direction 96 by contracting the piston rod 78, the gear plate 72 contracts in the gear track 80 in the direction 98 (see FIG. 9A below). See also).

  FIG. 8B is a side view 290 of the gear plate 72, the cylindrical gear head 74, and the guide track 80, as indicated by the directional arrows 282 in FIG. 8A. Cylindrical gear head 74 is positioned such that surface 202 is positioned within arcuate channel 234. The angled channels 204 and teeth 206 of the cylindrical gear head 74 extend through the gear window 236 and include the angled channels 172 and linear teeth 176 of the gear plate 72 disposed within the gear channel 228. Combined. FIG. 8C is an end view 300, as indicated by the directional arrow 284 in FIG. 8A, further illustrating the relationship between the gear plate 72, the cylindrical gear head 74, and the guide track 80. FIG.

  FIG. 9A is a top view 310 depicting the gear plate 72 in a fully contracted position within the gear track 80, with the liner plate 32a being contracted against the cross member 36a. For clarity purposes, the cylindrical gear head 74 is not shown. Angled channel 172 and linear teeth 176 are visible through gear window 236. The liner plate 32a is shown as being coupled to the gear plate 72 using a plurality of fasteners 128 that extend through the liner plate 32a to the gear plate 72. In one embodiment, the fastener 128 is coupled by screwing the liner plate 32 a to the gear plate 72.

  FIG. 9B is a top view 320 illustrating the gear plate 72 extending at least partially from the gear track 80, with the liner plate 32a being separated from the cross member 36a. Again, the cylindrical gear head 74 is not shown, and the angled channel 172 and liner teeth 176 can be seen through the gear window 236.

  FIG. 10A is a schematic diagram 330 illustrating one exemplary embodiment of a gear drive assembly 332 according to the present invention. The gear drive assembly 332 includes a cylindrical gear head 74, a cylinder 76, a piston rod 78, and a cylindrical sleeve 334. The cylindrical gear head 74 and the piston rod 78 are configured to be slidably inserted into the cylindrical sleeve 334. The cylinder 76 is screwed and coupled to a cylindrical sleeve 334, and the O-ring 336 becomes a sealing material. A window 338 along the axis of the cylindrical sleeve 334 partially exposes the angled channel 204 and the linear teeth 206. A fitting 342, such as a pneumatic or hydraulic fitting, is shown as being threadably coupled to the opening 82. The cylinder 76 further includes an opening 344 that is accessible through the cross member 36a.

  The gear drive assembly 332 is configured to slidably insert into a cylindrical gear shaft 134 (shown by the dashed line), and the window 338 intersects the gear slot 126 and includes the angled channel 204 and line. The teeth 206 are exposed in the gear slot 126. When gear track 80 and gear plate 72 (not shown) are first slidably inserted into gear slot 126, gear drive assembly 332 is slidably inserted into cylindrical gear shaft 134. Sometimes the angled channels 204 and linear teeth 206 of the cylindrical gear head 74 slidably engage and mate with the angled channels 172 and linear teeth 176 of the gear plate 72.

  In one embodiment, the key 340 is coupled to the cylindrical gear head 74 and resides in the key slot 342 in the cylindrical sleeve 334. The key 340 prevents the cylindrical gear head 74 from rotating within the cylindrical sleeve 334. Both key 340 and key slot 342 also control maximum expansion and contraction of cylindrical gear head 74 within cylindrical sleeve 334. Thus, in one embodiment, the key 340 can be adjusted to control the extension distance of the liner plate 32a toward the inside of the mold cavity 46. FIG. 10A is a top view 350 of a cylindrical shaft 334, as illustrated in FIG. 10B, further illustrating the key 340 and key slot 342. FIG.

  FIG. 11A is a top view illustrating one exemplary embodiment of a mold assembly 360 in accordance with the present invention for forming two concrete blocks. The mold assembly 360 includes a mold frame 361 having side members 34a, 34b and cross members 36a-36c that are coupled together to form a pair of mold boxes 42a and 42b. The mold box 42a has movable liner plates 32a-32d and corresponding removable liner faces 33a-33d and is configured to form a mold cavity 46a. Mold box 42b includes moveable liner plates 32e-32h and corresponding removable liner faces 33e-33h and is configured to form a mold cavity 46b.

  Each movable liner plate has an associated gear drive assembly, as indicated by 50a-50h, which is disposed within an adjacent mold frame member. Each movable liner plate is illustrated in a position extended by a corresponding gear plate as indicated by 72a-72h. As will be described below, the moveable liner plates 32c and 32e share a gear drive assembly 50c / e, and the gear plate 72e has a plurality of corresponding angled channels facing upwards, Plate 72c has a plurality of correspondingly angled channels facing downward.

  FIG. 11B is a schematic diagram illustrating a gear drive assembly, eg, gear drive assembly 50c / e, in accordance with the present invention. FIG. 11B illustrates a view of the gear drive assembly 50c / e as viewed from section AA through the cross member 36c of FIG. 11A. The gear drive assembly 50c / e includes a single cylindrical gear head 76c / e, which has angled channels 204c and 204e on opposing faces. Cylindrical gear head 76c / e fits within arcuate channel 234c of gear track 80c and arcuate channel 234e of gear track 80d so that angled channels 204c and 204e are angled of gear plate 72c. The channel 172c and the angled channel 172e of the gear plate 72e are slidably assembled.

  Angled channels 172c and 204c and angled channels 172e and 204e exist relative to each other when the cylindrical gear head 76c / e is extended (eg, out of FIG. 11B). The gear plate 72c moves toward the inside of the mold cavity 46a in the direction 372, and the gear plate 72e moves toward the inside of the mold cavity 46b in the direction 374. Similarly, when the cylindrical gear head 76c / e is contracted (eg, in FIG. 11B), the gear plate 72c moves away from the inside of the mold cavity 46a in the direction 376, and the gear plate 72e moves away from the inside of mold cavity 378 in direction 378. Again, the cylindrical gear heads 76c / e and the gear plates 72c, 72c may be any suitable shape.

  FIG. 12 is a perspective view illustrating a portion of one exemplary embodiment of a mold assembly 430 in accordance with the present invention. The mold assembly includes moveable liner plates 432a through 432l for molding multiple concrete blocks simultaneously. Mold assembly 430 includes a drive system assembly 431, which has side members 434a and 434b and cross members 436a and 436b. For illustration purposes, the side member 434a is indicated by a dashed line. Mold assembly 430 further includes split plates 437a-437g.

  The movable liner plates 432a to 432l and the split plates 437a to 437g together form mold cavities 446a to 446f, and each mold cavity is configured to form a concrete block. Accordingly, in the illustrated embodiment, the mold assembly 430 is configured to form six blocks simultaneously. However, it is clear from the figure that the mold assembly 430 can be easily modified to form a number of blocks that are not six simultaneously.

  In the illustrated embodiment, side members 434a and 434b each have a corresponding gear drive assembly to move movable liner plates 432a through 432f and 432g through 432l, respectively. For illustration purposes, only the gear drive assembly 450 associated with the side members 434a and the corresponding movable liner plates 432a-432g is shown. Gear drive assembly 450 includes first gear elements 472a-472f and second gear elements 474 that are selectively coupled to corresponding movable liner plates 432a-432f, respectively. In the illustrated embodiment, the first gear elements 472a-472f and the second gear element 474 are shown as being cylindrical in shape. However, any suitable shape can be used.

  Second gear element 474 is selectively coupled to a cylinder piston (not shown) via piston rod 478. In one embodiment described in more detail below (see FIG. 12), the second gear element 474 is united with the cylinder piston to form a single component.

  In the illustrated embodiment, each of the first gear elements 472a-472b further includes a plurality of substantially parallel angled channels 484, the channels being a plurality of substantially parallel channels on the second gear element 474. Slidably engages and mates with a channel 486 having a generally parallel angle. When the second gear element 474 is moved in the direction indicated by arrow 492, each of the movable liner plates 432a-432f moves in the direction indicated by arrow 494. Similarly, when the second gear element 474 is moved in the direction indicated by arrow 496, each of the movable liner plates 432a-432f is directed in the direction indicated by arrow 498. Moving.

  In the illustrated embodiment, the angled channel and angled channel 486 on each of the first gear elements 432a-432f are at the same angle. Thus, when the second gear element 474 moves in directions 492 and 496, each moveable liner plate 432a-432f moves the same distance in directions 494 and 498, respectively. In one embodiment, the second gear element 474 includes a plurality of groups of substantially parallel angled channels, each group corresponding to a different element of the first gear elements 472a-472f. . In one embodiment, each group of angled channels and corresponding first gear elements have different angles, and each movable liner plate 432a-432f includes a second gear element 474 in a direction 492. And 496 in response to being moved, moving different distances in directions 494 and 498, respectively.

  FIG. 13 is a perspective view illustrating a gear drive assembly 500, a corresponding movable liner plate 502, and a removable liner face 504 in accordance with the present invention. For purposes of illustration, the frame assembly including side members and cross members is not shown. Gear drive assembly 500 includes a double rod end double acting pneumatic cylinder piston 506, which is a hollow piston rod 508 having a cylinder body 507, a first rod end 510 and a second rod end 512. And have. Gear drive assembly 500 further includes a pair of first gear elements 514a and 514b coupled to a selectively movable liner plate 502, each first element 514a and 514b being a plurality of substantially parallel elements. It has angled channels 516a and 516b.

  In the illustrated embodiment, the cylinder body 507 of the cylinder piston 506 includes a plurality of substantially parallel angled channels 518 that engage and slide the angled channels 516a and 516b. Combine as possible. In one embodiment, the cylinder body 507 is configured to slidably insert and couple into a cylinder sleeve having an angled channel 518.

  In one embodiment, the cylinder piston 506 and the piston rod 508 are disposed within the drive shaft of the frame member, eg, the drive shaft 134 of the cross member 36a, and the rod end 510 is coupled to the frame member, eg, the side member 34b. And extending through the member, the second rod end 512 is coupled to a frame member, eg, side member 34a, and extends through the member. The first rod end 510 and the second rod end 512 are configured to receive and provide compressed air to drive a double acting cylinder piston 506. Since the piston rod 508 is fixed to the side members 34a and 34b via the first rod end 510 and the second rod end 512, the cylinder piston 506 is fixed to the first rod end 510 and the second rod end. In response to compressed air received via 512, it moves along the axis of piston rod 508 in the direction as indicated by arrows 520 and 522.

  When compressed air is received via the second rod end 512 and exhausted via the first rod end 510, the cylinder piston 506 moves within the drive shaft, eg, the drive shaft 134, in the direction 522. To move the first gear elements 514a and 516b, the corresponding liner plate 502, and the liner face 504 in the direction indicated by arrow 524. Conversely, when compressed air is received via the first rod end 510 and exhausted via the second rod end 512, the cylinder piston 506 is directed in a gear shaft, such as the gear shaft 134, in the direction. Moving toward 520, the first gear elements 514a and 516b, the corresponding liner plate 502, and the liner face 504 are moved in the direction indicated by arrow 526.

  In the illustrated embodiment, the cylinder piston 506 and the first gear elements 514a and 514b are shown as being substantially cylindrical in shape. However, any suitable shape can be used. Further, in the illustrated embodiment, the cylinder piston 506 is a double rod end double acting cylinder. In one embodiment, the cylinder piston 506 is a single rod end double acting cylinder that has only a single rod end 510 that is coupled to a frame member, eg, side member 34b. In such an embodiment, the compressed air is directed to the cylinder piston via a single rod end 510 and a flexible pneumatic connection made to the cylinder piston 506 through the side member 34a via the gear shaft 134. Provided. Furthermore, the cylinder piston 506 includes a hydraulic cylinder.

  14 is a top view of a portion (as illustrated by FIG. 12) of a mold assembly 430 having a drive assembly 550, in accordance with one embodiment of the present invention. The drive assembly 550 includes first drive elements 572a-572f that are selectively coupled to corresponding liner plates 432a-432f through side openings 434a, for example via openings 433. . Each of the first drive elements 572a-572f is further coupled to a master bar 573. The drive assembly 550 further includes a double rod end hydraulic piston assembly 606 that includes a double acting cylinder 607 and a hollow piston rod 608 having a first rod end 610 and a second rod end 612. And have. First rod end 610 and second rod end 612 are fixed and coupled to removable housing 560 and extend through the housing, which is coupled to side member 434a and surrounds drive assembly 550. It is out. The first rod end 610 and the second rod end 612 are each coupled to a hydraulic fitting 620 that is connected to an external hydraulic system 624 via lines 622a and 622b and is hollow. The hydraulic fluid is transferred to the double-acting cylinder 607 via the piston rod 608, and the hydraulic fluid is transferred from the double-acting cylinder 607.

  In one embodiment as shown, the first drive elements 572b and 572e include a plurality of substantially parallel angled channels 616, the channels 616 having a plurality of substantially parallel angles. The channel 618 is slidably assembled with the channel 618, which forms a second drive element. In one embodiment, as illustrated above by FIG. 12, an angled channel 618 is formed on the double acting cylinder 607 of the hydraulic piston assembly 606, and the double acting cylinder 607 is a second acting cylinder 607. Forming a drive element; In other embodiments as described below by FIGS. 15A-15C, the second drive element is separated from the double-acting cylinder 607 and is operably coupled to the double-acting cylinder 607.

  When hydraulic fluid is delivered from the second rod end 612 into the double acting cylinder 607 via the fitting 620 and the hollow piston rod 608, the hydraulic fluid is drained from the first rod end 610; Double acting cylinder 607 and angled channel 618 move along piston rod 608 towards second rod end 612. As the double acting cylinder 607 moves toward the second rod end 612, the angled channel 618 interacts with the angled channel 616 and the first drive elements 572b and 572e and the corresponding ones. Liner plates 432b and 432e are driven toward mold cavities 446b and 446e, respectively. Further, since each of the first elements 572a-572f is coupled to the master bar 573, driving the first gear elements 572b and 572e toward the inside of the mold cavities 446b and 446e is also the first Drive elements 572a, 572c, 572d and 572f and corresponding liner plates 432a, 432c, 432d and 432e are moved toward mold cavities 446a, 446c, 446d and 446f, respectively. Conversely, delivery of hydraulic fluid from the first rod end 610 into the double acting cylinder 607 via the fitting 620 and the hollow piston rod 608 may cause the double acting cylinder 607 to move to the first rod. Moving toward the end 610, the liner plate 432 is moved away from the inside of the corresponding mold cavity 446.

  In one embodiment, the drive assembly 550 further includes a support shaft 626, eg, support shafts 626a and 626b, which is coupled between the removable housing 560 and the side member 434a and extends through the master bar 573. Is growing. Since the double acting cylinder 607 is moved by delivering / draining hydraulic fluid from the first rod end 610 and the second rod end 612, the master bar 573 moves back and forth along the support shaft 626. Moving. Because the support shaft is coupled to the stationary element of the mold assembly 430, the support shafts 626a and 626b are moved when the liner plate 432, drive element 572 and master bar 573 move toward and away from the mold cavity 446. , Provides support and rigidity to the liner plate 432 and the drive elements 572 and master bar 573.

  In one embodiment, the drive assembly 550 further includes a pneumatic fitting 628 that is configured to connect to an external compressed air system 632 via line 630 and provide compressed air to the housing 560. Yes. By receiving compressed air into the removable housing 560 via the pneumatic fitting 628, the air pressure inside the housing 560 becomes positive with respect to the outside air pressure, and the air is continuously sealed in any manner. The first drive element 572 extends through the side member 434a through a non-opening, such as the opening 433, and is pushed out of the housing 560. By maintaining positive air pressure and pushing air out through such an unsealed opening, dust and debris generation, other unwanted contamination from entering the housing 560, and drive assembly Contamination is reduced.

  The first rod end 610 and the second rod end 612 are each coupled to a hydraulic fitting 620, which is connected to an external hydraulic system 624 via lines 622a and 622b to provide hydraulic fluid. Is transferred to and from the double-acting cylinder 607 through a hollow piston rod 608.

  FIG. 15A is a top view illustrating a portion of one embodiment of a drive assembly 550 in accordance with the present invention. The drive assembly 550 includes a double rod end hydraulic piston assembly 606 that includes a double acting cylinder 607 and a hollow piston rod 608 having a first rod end 610 and a second rod end 612. And the rod end is coupled to and extends through the removable housing 560.

  As shown, the double acting cylinder 607 is slidably fitted inside a machined opening 641 in the second gear element 640 and a hollow piston rod 608 is attached to the removable end cap 642. Extends through. In one embodiment, the end cap 646 is threadedly inserted into the machined opening 641 and the end cap 646 contacts the double acting cylinder 607 to secure the double acting cylinder 607 and double acting. The expression cylinder 607 is held fixed relative to the second drive element 640. Second drive element 640 includes a plurality of substantially parallel angled channels 618 in place of the angled channels that are an integral part of double acting cylinder 607. Referring to FIG. 14, the angled channel 618 of the second gear element 640 is configured to slidably mate with the angled channel 616 of the first gear elements 572b and 572e.

  The second gear element 640 further includes a guide rail 644 that is slidably coupled to a linear bearing block 646, which is installed in the housing 560. Delivering hydraulic fluid to the double acting cylinder 607 via the first rod end 610 and the second rod end 612 and the double acting hydraulic fluid as described above with reference to FIG. Discharging from the cylinder 607 moves the double-acting cylinder 607 along the hollow piston rod 608. The double gear cylinder 607 is “locked” by the end cap 642 within the machined shaft 641 of the second gear element 640 so that the second gear element 640 moves along the hollow piston rod 608. Then, it moves together with the double acting cylinder 607. As the second drive element 640 moves along the hollow piston rod 608, the linear bearing block 646 guides and secures the guide rail 644, thereby guiding the drive element 640, and Secure and reduce unwanted movement in the second drive element 640. The second drive element intersects the hollow piston rod 608 at a right angle.

  FIG. 15B is a cross-sectional view along A-A of a portion of the drive assembly 550 illustrated by FIG. 15A. Since the second drive element 640 is moved along the piston rod 608 by the double acting cylinder 607, the guide rail 644 is slidably fitted into the linear bearing track 650 and supported by the bearing 652. ing. In one embodiment, the linear bearing block 646 b is coupled to the housing 560 by bolts 648.

  FIG. 15C is a longitudinal cross-sectional view along B-B of a portion of the drive assembly 550 of FIG. It is shown as being. In one embodiment, end caps 642a and 642b are threadably inserted into the end of second drive element 640 and abut each end of double acting cylinder 607. A hollow piston rod 608 extends through end caps 642a and 642b and has a first rod end 610 and a second rod end 612 that are coupled to and pass through the housing 560. And stretched. A divider 654 is coupled to the piston rod 608 and divides the double acting cylinder 607 into a first chamber 656 and a second chamber 658. The first portion 660 and the second portion 662 allow the hydraulic fluid to pass through the first chamber 656 and the first chamber 610 via the first rod end 610 and the hydraulic fitting 620 associated with the second rod end 612, respectively. Two chambers 658 can be pumped and discharged from the first chamber 656 and the second chamber 658.

  When hydraulic fluid is pumped into the first chamber 656 via the first rod end 610 and the first port 660, the double acting cylinder 607 moves along the hollow piston rod 608, Moving toward the first rod end 610, the hydraulic fluid is drained from the second chamber 658 via the second port 662 and the second rod end 612. The double acting cylinder 607 is secured within the shaft 641 by the end caps 642a and 642b so that the second drive element 640 and the angled channel 618 move toward the first rod end 610. Similarly, when hydraulic fluid is pumped into the second chamber 658 via the second rod end 612 and the second port 662, the double-acting cylinder 607 moves into the hollow piston rod 608. Along the second rod end 612, and the hydraulic fluid is discharged from the first chamber via the first port 660 and the first rod end 610.

  FIG. 16 is a side view of a portion of a drive assembly 550 as shown by FIG. 14, illustrating a typical liner plate, such as liner plate 432a, and a corresponding removable liner face 400. FIG. Liner plate 432a is coupled to second drive element 572a by bolt connection 670, which in turn is coupled to master bar 573 by bolt connection 672. The lower portion of liner face 400 is coupled to liner plate 432a by bolt connection 674. In one embodiment as shown, the liner plate 432a includes a raised “rib” 676 that runs along the upper edge of the liner plate 432a by the length of the liner plate 432a. Yes. Channels 678 in liner face 400 overlap and mate with raised “ribs” 676 to form a “boltless” connection between liner plate 432 a and the upper edge of liner face 400. Such a combination connection securely joins the upper portion of the liner face 400 to the liner plate 432 in the area of the liner face 400, otherwise it is too narrow and faces the mold cavity 446a. On the surface of 400, the bolt connection between the liner face 400 and the liner plate 432a is not allowed to be used without the bolts being visible.

  In one embodiment, the liner plate 432 includes a heater 680 that maintains the temperature of the corresponding liner face 400 at the desired temperature during the concrete curing process so that the concrete in the corresponding mold cavity 446 It is configured to prevent adhesion to the surface of the liner face 400. In one embodiment, the heater 680 includes an electric heater.

  17 is a block diagram illustrating one embodiment of a mold assembly, eg, mold assembly 430 of FIG. 14, in accordance with the present invention, further including a controller 700, which includes a drive assembly, eg, By controlling the operation of drive assembly 550, the movement of a movable liner plate, eg, liner plate 432, is configured to coordinate with the operation of concrete block machine 702. In one embodiment as shown, the controller 700 comprises a programmable logic controller (PLC).

  As described above with respect to FIG. 1, the mold assembly 430 is selectively coupled to the concrete block machine 702, generally through a plurality of bolt connections. In operation, first, the concrete block machine 702 places the pallet 56 under the mold box assembly 430. The concrete feed box 704 then fills the mold cavity of the assembly 430, eg, mold cavity 446, with concrete. Next, the head shoe assembly 52 is lowered onto the mold assembly 430 to compress the concrete in the mold cavity 446 either hydraulically or mechanically, along with the shaking table on which the pallet 56 is placed. The assembly 430 is vibrated simultaneously. After compression and vibration is complete, the head shoe assembly 52 and pallet 56 are lowered down against the mold cavity 446 and the molded concrete block is ejected from the mold cavity 446 onto the pallet 56. Next, the head shoe assembly 52 is lifted and a new pallet 56 is moved to a position below the mold cavity 446. The above process is repeated continuously, and each such iteration is usually referred to as a cycle. In particular, for mold assembly 430, each such cycle produces six concrete blocks.

  The PLC 700 is configured to coordinate the expansion of the liner plate 432 into the mold cavity 446 and the contraction of the liner plate 432 out of the mold cavity 446 with the operation of the concrete block machine 702 as described above. . At the start of the cycle, the liner plate 432 is fully retracted from the mold cavity 446. In one embodiment, referring to FIG. 14, the drive assembly 550 includes a pair of sensors, eg, proximity switches 706a and 706b, and the position of the master bar 573 and the corresponding movable bar coupled to the master bar 573. The position of the liner plate 432 is monitored. As illustrated in FIG. 14, proximity switches 706a and 706b each sense when liner plate 432 is in an extended or contracted position relative to mold cavity 446. It is configured.

  In one embodiment, after the pallet 56 is placed under the mold assembly 430, the PLC 700 receives a signal 708 from the concrete block machine 702, which indicates that the concrete feed box 704 sends the concrete to the mold cavity 446. Indicates that it is ready to be transported. PLC 700 checks the position of movable liner 432 based on signals 710a and 710b received from proximity switches 706a and 706b, respectively. When the liner plate 432 is in the retracted position, the PLC 700 provides a liner extension signal 712 to the hydraulic system 624.

  In response to the liner extension signal 712, the hydraulic system 624 begins pumping hydraulic fluid to the second rod end 612 of the piston assembly 606 via the path 622b and from the first rod end 610. It begins to receive hydraulic fluid via path 622a, thereby causing double-acting cylinder 607 to begin moving liner plate 432 toward the inside of mold cavity 446. When proximity switch 706a senses master bar 573, proximity switch 706a provides a signal 710a to PLC 700 indicating that liner plate 432 has reached the desired extended position. In response to signal 710a, PLC 700 directs hydraulic system 624 to stop pumping hydraulic fluid into piston assembly 606 via signal 712 and signal 714 is sent to concrete block machine 702. And shows that the liner plate 432 has been stretched.

  In response to signal 714, concrete feed box 704 fills mold cavity 446 with concrete, and head shoe assembly 52 is lowered onto mold assembly 430. After the concrete compression and vibration is complete, the concrete block machine 702 provides a signal 716 indicating that the molded concrete block is ready to be ejected from the mold cavity 446. In response to signal 716, PLC 700 provides liner contraction signal 718 to hydraulic system 624.

  In response to the liner contraction signal 718, the hydraulic system 624 begins pumping hydraulic fluid to the first rod end 610 via path 622a and second hydraulic fluid via path 622b. From the rod end 612, thereby causing the double acting cylinder 607 to move the liner plate 432 away from the inside of the mold cavity 446. When proximity switch 706b senses master bar 573, proximity switch 706b provides signal 710b to PLC 700, which indicates that liner plate 432 has reached the desired retracted position. In response to signal 710b, PLC 700 instructs via signal 718 that hydraulic system 624 stops pumping hydraulic fluid into piston assembly 606, and signal 720 is sent to concrete block machine 702. And the signal indicates that the liner plate 432 has been deflated.

  In response to signal 720, head shoe assembly 52 and pallet 56 eject the formed concrete block from mold cavity 446. The concrete block machine 702 then contracts the head shoe assembly 52 and places a new pallet 56 under the mold assembly 430.

  In one embodiment, PLC 700 is further configured to control the supply of compressed air to mold assembly 430. In one embodiment, the PLC 700 provides a status signal 722 to the compressed air system 630 that indicates when the concrete block machine 702 and the mold assembly 430 are operating and molding a concrete block. When in operation, the compressed air system 632 provides compressed air to the housing 560 of the mold assembly 420 via line 630 and pneumatic fitting 628, and dust / dirt and other debris enters the drive assembly 550. Reduce the likelihood of doing so. When not in operation, the compressed air system 632 does not provide compressed air to the mold assembly 430.

  Although the above description regarding the controller 700 relates to controlling a single piston assembly, eg, a drive assembly that uses only the piston assembly 606 of the drive assembly 500, the controller 700 uses multiple piston assemblies. And can be configured to control a drive assembly using multiple pairs of proximity switches, eg, 706a and 706b. In such an example, the hydraulic system 624 is coupled to each piston assembly via a pair of hydraulic lines, eg, lines 622a and 622b. In addition, the PLC 700 receives a plurality of position signals, each applicable proximity switch indicates that all movable liner plates are in the extended position, and each applicable proximity switch includes all movable liners. Only when it indicates that the plate is in the contracted position, the mold cavity is filled with concrete, respectively, allowing the molded blocks to be discharged.

  18A-18C illustrate a portion of an alternative embodiment of a drive assembly 550 as illustrated by FIGS. 15A-15C. 18A is a top view of second gear element 640 that is driven by a screw drive system 806 instead of a piston assembly, eg, piston assembly 606. FIG. The screw drive system 806 includes a threaded screw 808, such as an acme or ball screw, and an electric motor 810. A threaded screw 808 is connected through the corresponding threaded shaft 812 and extends longitudinally through the second gear element 640. The threaded screw 808 is coupled to the first bearing assembly 814a at a first end and to the motor 810 at a second end via the second bearing assembly 814b. The motor 810 is selectively coupled via a motor mount 824 to the mold assembly housing 560 and / or to the side / cross member, eg, cross member 434a.

  In a manner similar to that described by FIG. 15A, the second gear element 640 includes a plurality of angled channels 618, which are the first gear as shown by FIG. It slidably mates and meshes with the angled channel 616 of elements 572b and 572e. Since the second gear element 640 is coupled to the linear bearing block 646, when the motor 810 is driven to rotate the screw-shaped screw 808 in the counterclockwise direction 816, the second gear element 640 is coupled to the linear bearing block 646. Gear element 640 is driven along a linear bearing track 650 in direction 818. As the second gear element 640 moves in the direction 818, the angled channel 618 interacts with the angled channel 616 and is illustrated by a liner plate, eg, FIGS. The liner plates 432a to 432f are extended toward the inside of the mold cavities 446a to 446f.

  When the motor 810 is driven to rotate the screw-shaped screw 808 in the clockwise direction 820, the second gear element 640 is driven in the direction 822 along the linear bearing track 650. Is done. As the second gear element 640 moves in the direction 822, the angled channel 618 interacts with the angled channel 616 and is illustrated by a liner plate, eg, FIGS. The liner plates 432a to 432f are contracted away from the inside of the mold cavities 446a to 446f. In one embodiment, the distance that the liner plate is stretched toward the inside of the mold cavity and the distance that it is shrunk away from the inside of the mold cavity is a pair of proximity switches 706a and Control is performed based on 706b. In an alternative embodiment, the travel distance of the liner plate is controlled based on the number of revolutions of the screw-like screw 808 driven by the motor 810.

  18B and 18C respectively illustrate a cross-sectional view along AA and a longitudinal cross-sectional view along BB of the drive assembly 550 as illustrated by FIG. In an alternative embodiment, the motor 810 is illustrated as being located outside the housing 560, but the motor 810 is installed within the housing 560.

  As mentioned above, concrete blocks (generally also referred to as concrete masonry units (CMUs)) are various types of blocks, such as patio blocks, pavers, lightweight blocks, gray blocks, building units, and Includes retaining wall blocks. The terms concrete block, masonry block, and concrete masonry unit are used interchangeably herein and are suitable for being formed by the assembly, system, and method of the present invention. It is intended to include units. Furthermore, although described herein as primarily including and using concrete, dry cast concrete, or other concrete mixtures, the systems, methods, and concrete masonry units of the present invention are described. Is not limited to such materials and is intended to include the use of any material suitable for the formation of such blocks.

  FIG. 19 is a flow diagram illustrating one exemplary embodiment of a process 850 for forming a concrete block using a mold assembly in accordance with the present invention, illustrated by FIG. Reference is made to such a mold assembly 30. Process 850 begins at 852 and mold assembly 30 is bolted to the concrete block machine, for example, via side members 34a and 34b. For the purpose of simplifying the diagram, the concrete block machine is not shown in FIG. Examples of concrete block machines to which mold assemblies can be adapted for use include models manufactured by Columbia and Besser. In one embodiment, the attachment of the mold assembly 30 to the concrete block machine at 852 further includes attachment of a core bar assembly (not shown in FIG. 1, but known to those skilled in the art), the core bar assembly. Are placed in the mold cavity 46 and create a space in the formed block according to the design needs of the particular block. In one embodiment, the mold assembly 30 further includes a head shoe assembly 52, which is also bolted to a concrete block machine at 852.

  At 854, one or more liner plates, e.g., liner plates 32a-32d, are stretched by a desired distance to form a mold cavity 46, the cavity being negative of the desired shape of the formed concrete block. Have As described in detail below, the number of movable liner plates may vary according to the particular implementation of the mold assembly 30 and the type of concrete block being formed. At 856, after the one or more liner plates are stretched, the concrete block machine lifts the shaking table on which the pallet 56 is placed, and the pallet 56 contacts the mold assembly 30 and forms the bottom for the mold cavity 46. To do.

  At 858, the concrete block machine moves the feed box drawer (not shown in FIG. 1) to a position above the open top of the mold cavity 46 to fill the mold cavity with the desired concrete mixture. After the mold cavity 46 is filled with concrete, the feed box drawer is shrunk and at 860 the concrete block machine lowers the head shoe assembly 52 over the mold cavity 46. The head shoe cavity 52 is configured to fit the dimensions and other unique configurations of each mold cavity, eg, mold cavity 46.

  At 862, the concrete block machine compresses the concrete (eg, hydraulically or mechanically) and at the same time vibrates the mold assembly 30 through the shaking table on which the pallet 56 is placed. Performing both compression and vibration provides a level of hardness that allows the concrete to substantially fill any space in the mold cavity 46 and allows the formed concrete block to be removed from the mold cavity 46 ( “Before curing”), let concrete reach quickly.

  In step 864, the one or more movable liner plates 32 are contracted away from the inside of the mold cavity 46. After the liner plate 32 is deflated, the mold assembly 30 remains stationary, but by moving the head shoe assembly 52 downward along the shaking table and pallet 56, the concrete block machine The formed concrete block is removed from the mold cavity 46. The head shoe assembly 52 is vibrated until the lower edge of the head shoe assembly 52 falls below the lower edge of the mold cavity 46 and the formed block is ejected from the mold cavity 46 onto the pallet 56. The platform and pallet 56 are lowered. The conveyor system then moves the pallet 56 and carries the formed blocks away from the concrete block machine to an oven where the formed blocks are cured. At 868, the head shoe assembly 56 is lifted to the initial starting position and the process 850 returns to 854 and the process described above is repeated to create additional concrete blocks.

  FIG. 21 is a perspective view of one embodiment of a masonry block 900 in accordance with the present invention. The masonry block 900 includes a first main surface 902, a second main surface 904, a first horizontal surface 906, a second horizontal surface 908, a first end surface 910, and a second end surface 912. Including. In one embodiment, the first major surface 902 and the second major surface 904 include a front surface and a rear surface, respectively, and the first lateral surface 906 and the second lateral surface 908 are the top and bottom surfaces of the masonry block 900, respectively. including. In one embodiment as shown, a pair of openings or hollow cores 914 extend through the masonry block 900 from the first lateral surface 906 to the second lateral surface 908. Masonry block 900 is sometimes called a gray block.

  In one embodiment, as depicted by FIG. 21, the first major surface 902 includes a desired three-dimensional texture or pattern that is a movable liner plate, eg, a movable liner plate. 32b (see FIG. 1) is applied to the first major surface during the block molding process, and the liner plate 32b contains the desired three-dimensional pattern of negatives. In one embodiment, both the first major surface 902 and the second major surface 904 include a three-dimensional texture or pattern provided by a corresponding movable liner plate. The desired three-dimensional texture or pattern is almost any texture or pattern, such as natural stone, layered stone, mortared stones, text, and any number of desired graphics or designs possible. It should be noted that a gray block has one or more textured surfaces and is sometimes referred to as a building unit.

  In accordance with the present invention, at least one of the first end surface 910 and the second end surface 912 of the masonry block 900 is non-planar and is configured to overlap a non-planar end surface of a similar masonry block. When arranged side by side to form a wall or other structure, the non-planar end face is adjacent to the masonry block (see FIG. 25 below). In one embodiment as shown in FIG. 21, the first end surface 910 is non-planar and is formed by a flange 916 that includes a first major surface 902 and a second major surface 904. Extending along an edge shared with the first lateral surface 906. Similarly, the flange 916 defines a notch 918 that extends between the first major surface 902 and the second major surface 904 along an edge shared with the second lateral surface 908. Extending substantially parallel to the flange 916. In one embodiment, as described in more detail below by FIGS. 26A-26D, the flange 916 is formed through the movement of a movable liner plate in conjunction with the pallet.

  The masonry block 900 has a width (W) 920, a depth (D) 922, and a height (H) 924. Flange 916 has a height (H1) 926 and notch 918 has a height (H2) 928. Flange 916 and notch 918 have a width (W 1) 930. In one exemplary embodiment, H1 926 and H2 928 are substantially equal to 1.5 times the height H924 of the masonry block 900. The masonry block 900 can be formed in various dimensions, which are standard dimensions such as 4 inches (H) x 12 inches (D) x 9 inches (W) and 8 inches (H) x 12 inches (D ) X18 inches (W) included. Further, although illustrated as having a pair of hollow cores 914, the masonry block 900 may include more or less than two hollow cores. For example, in one embodiment, the masonry block 900 may be a solid configuration and may not include a hollow core.

  FIG. 22 is a perspective view generally illustrating one embodiment of a masonry block 950 in accordance with the present invention. The masonry block 950 is similar to the masonry block 900 of FIG. 21, but in addition to the first end surface 910 being non-planar, the second end surface 912 is also non-planar in shape, When configured to overlap a non-planar end face of a masonry block and arranged side by side to form a wall or other structure, the masonry block 950 is adjacent to the similar masonry block (see below). (See FIG. 25).

  As illustrated by FIG. 22, in one embodiment, the second end surface 912 is non-planar and is formed by a flange 952, which includes a first major surface 902 and a second major surface 904. Between and along the edge shared with the second lateral surface 908. Similarly, the flange 952 defines a notch 954 that is between the first major surface 902 and the second major surface 904 along an edge shared with the first lateral surface 906. Extends substantially parallel to 952. The flange 952 has a height (H3) 956 and the notch 954 has a height (H4) 958. The flange 952 and the notch 952 have a width (W2) 960. In one exemplary embodiment, H3 956 and H4 958 are substantially equal to 1.5 times the height of H924, and W2 960 is substantially equal to W1 930 of the masonry block 900 of FIG.

  FIG. 23 is a perspective view generally illustrating one embodiment of a masonry block 970 in accordance with the present invention. The masonry block 970 is similar to the masonry block 900 of FIG. 21, but in addition to the first end surface 910 being non-planar, the second end surface 912 is also non-planar in shape, When configured to overlap a non-planar end face of a masonry block and arranged side by side to form a wall or other structure, the masonry block 970 is adjacent to the similar masonry block (see below). (See FIG. 25).

  In one embodiment, as illustrated by FIG. 23, the second end surface 912 is non-planar and is formed by a flange 972 that is formed between the first major surface 902 and the second major surface 904. In between, it extends along an edge shared with the first lateral surface 906. Similarly, the flange 972 defines a notch 974, which is a flange between the first major surface 902 and the second major surface 904 along an edge shared with the second lateral surface 908. 972 extending substantially parallel to 972. The flange 972 has a height (H5) 976 and the notch 974 has a height (H6) 978. The flange 972 and the notch 972 have a width (W3) 980. In one exemplary embodiment, H5 976 and H6 978 are substantially equal to 1.5 times the height of H924, and W2 960 is substantially equal to W1 930 of the masonry block 900 of FIG.

  Blocks 900, 950, and 970 of FIGS. 21-23, such that non-planar end faces 910 and 912 include rectangular notches and rectangular flanges, eg, flange 916 and notch 918 of block 900 of FIG. Although illustrated above, the non-planar end face is not limited to such a rectangular configuration. For example, FIG. 24 is a perspective view illustrating one embodiment of a masonry block 990 according to the present invention, wherein the non-planar end surface 910 is formed by a flange 992, which is angled. Transition to notch 994 via element 996, flange 992, notch 994 and angled element 996 are formed through the movement of a movable liner plate as part of the block forming process.

  FIG. 25 is an illustration of a portion of a wall structure 1000 constructed using the gray blocks 900, 950, and 970 of FIGS. 21-23, the gray block having at least one non-planar end face; It is comprised so that it may overlap with the end surface of the same block according to this invention. As shown, the bonding pattern formed by blocks 900, 950, and 970 is not as grid-like as the pattern formed by conventional gray block 890, as illustrated by FIG. 20A.

  26A-26D are simplified diagrams of one implementation of the mold assembly 30 and a block forming process for forming the masonry block 950 of FIG. Mold assembly 30 is similar to the mold assembly illustrated above by FIG. 1, with side members 34a, 34b, cross members 36a, 36b, fixed liner plate 32b, and movable liner plates 32a, 32c, and 32d. Including. Drive assemblies 31a, 31c, and 31d extend movable liner plates 32a, 32c, and 32d toward the inside of mold cavity 46, and move liner plates 32a, 32c, and 32d from the inside of mold cavity 46. Each is coupled and configured to contract away. Liner faces 100a, 100c, and 100d are coupled to movable liner plates 32a, 32c, and 32d, respectively. Liner face 100a includes a flange 952 and notch 954 negative on end surface 912, liner face 100c includes a flange 916 and notch 918 negative on end surface 910, and liner face 100d is on major surface 902 of masonry block 950. Including the negative of the desired three-dimensional texture or pattern (see FIG. 22). Core bar assembly 1002 is disposed within mold cavity 46 and supports (not shown) extend from side members 34a, 34b and cross members 36a, 36b.

  FIG. 26A is a top view of mold assembly 30 illustrating moveable liner plates 32a, 32c, and 32d in a retracted position. FIG. 26B is a top view of the mold assembly 30 illustrating the movable liner plates 32a, 32c, and 32d in the extended position, where the concrete is ready to be introduced into the mold cavity 46. FIG. is made of. 26C and 26D illustrate a simplified cross-sectional view of the mold assembly along section line AA (see FIGS. 26A and 26B), further illustrating the head shoe assembly 52 and pallet 56. Yes. FIGS. 26C and 26D illustrate movable liner plates 32a, 32c, and 32d, respectively, in the retracted and extended positions. FIG. 26D further illustrates the head shoe assembly 52 disposed within the top of the mold cavity 46 after the concrete has been introduced. For simplicity of illustration, the core bar assembly 2002 is not shown in FIGS. 26C and 26D.

  Although illustrated herein with respect to a gray block, alternatively, overlapping non-planar end faces that provide an overlapping major surface or front face are also used for other types of masonry blocks, such as retaining wall blocks as well. obtain. FIGS. 27-32 illustrate examples of retaining wall blocks that use at least one non-planar end surface configured to overlap a non-planar end surface of a similar retaining wall block.

  FIG. 27 is a perspective view of one embodiment of a retaining wall block 1030 according to the present invention. The retaining wall block 1030 includes a front surface 1032, a back surface 1034, a top surface 1036, a bottom surface 1038, a first end surface 1040, and a second end surface 1042. In one embodiment, as illustrated by FIG. 27, the front surface 1032 includes a desired three-dimensional texture or pattern, which is a movable liner plate, such as a movable liner plate 32b (see FIG. 1). During the block molding process, the movable liner plate provided with the first major surface 1032 includes a negative of the desired three-dimensional pattern. The desired three-dimensional texture or pattern is almost any texture or pattern, such as natural stone, layered stone, mortared stones, text, and any number of desired graphics or designs possible.

  In accordance with the present invention, at least one of the first end surface 1040 and the second end surface 1042 of the masonry block 1030 is non-planar and is configured to overlap a non-planar end surface of a similar masonry block, When arranged side by side to form a wall or other structure, the masonry block 1030 is adjacent to the similar masonry block (see FIG. 33 below). In one embodiment as illustrated by FIG. 21, the first end surface 1040 is non-planar and is formed by a flange 1044, which faces the front major surface 10322 along an edge shared with the bottom surface 1038. And the back main surface 1034. Similarly, the flange 1044 defines a notch 1046 that extends substantially parallel to the flange 1044 between the front major surface 1032 and the rear major surface 1034 along an edge shared with the upper surface 1036. . In one embodiment, described in more detail below by FIGS. 33A-33D, the flange 1044 is formed through the movement of a movable liner plate in conjunction with a pallet.

The front surface 1032 has a width (W _f ) 1048 and the back surface 1034 has a width (Wr) 1050. In one embodiment as shown, Wr1050 is below Wf1048, and first side 1040 and second side 1042 are angled inwardly by angle (θ) 1052 from front 1032 to back 1034. Is attached. Retaining wall block 1030 has a height (H) 1054 and a depth (D) 1056. The flange 1044 has a height (H1) 1058 and the notch 1046 has a height (H2) 1060, each having a width (W1) 1062. In one exemplary embodiment, H1 1058 and H2 1060 are substantially equal to 1.5 times the height H of retaining wall block 1030. Retaining wall block 1030 can be formed in a variety of dimensions, which are standard dimensions such as 4 inches (H) x 12 inches (D) x 9 inches (W) and 8 inches (H) x 12 inches (D ) X18 inches (W) included.

  As shown, in one embodiment, the retaining wall block 1030 includes a setback flange 1064 that extends from the bottom surface 1038 along an edge formed by the back surface 1034. Retaining wall blocks, eg, retaining wall blocks 1030, are generally stacked side by side to form a retaining wall (see FIG. 33). The setback flange 1064 is configured to abut the back of similar blocks in the row of blocks below the retaining wall block 1030 and away from the front of the blocks in the lower row by the desired setback distance, 1032 is arranged. In one embodiment, illustrated in greater detail by FIG. 33C, setback flange 1064 is formed through the movement of a movable shoe assembly during block formation. Further, although not shown, the retaining wall block 1030 can be formed to have one or more hollow cores, which are similar to the hollow cores 914 of the masonry block 900 of FIG.

  FIG. 28 is a perspective view generally illustrating one embodiment of a masonry block 1070 according to the present invention. The masonry block 1070 is similar to the masonry block 1030 of FIG. 27, except that the second end face 1042 has a non-planar shape and is configured to overlap the non-planar end face of a similar masonry block. Or, when arranged side by side to form another structure, the masonry block 1042 is adjacent to the similar masonry block (see FIG. 33 below).

  In one embodiment, as illustrated in FIG. 28, the second end face 1042 is non-planar and is formed by a flange 1072, which is shared between the front face 1032 and the back face 1034 with the upper face 1036. Stretches along the edges that are. Similarly, the flange 1072 defines a notch 1074 that extends substantially parallel to the flange 1072 between the front face 1032 and the back face 1034 along an edge shared with the bottom face 1038. The flange 1072 has a height (H3) 1076 and the notch 1074 has a height (H4) 1078. Flange 1072 and notch 1074 have a width (W2) 1080. In one exemplary embodiment, H3 1076 and H4 1078 are substantially equal to 1.5 times the height of H 1054, and W2 1080 is substantially equal to W1 1062 of retaining wall block 1030 of FIG. Are equal.

  FIG. 29 is a perspective view generally illustrating one embodiment of a masonry block 1090 according to the present invention, which includes the retaining wall block 1030 of FIG. 27 and the retaining wall block 1070 of FIG. Includes combinations. Accordingly, the first end surface 1040 includes a flange 1044 and a notch 1046, and the second end surface 1042 includes a flange 1072 and a notch 1074, and both the first end surface and the second end surface are similar. When configured to overlap a non-planar end face of a masonry block and arranged side by side to form a wall or other structure, the masonry block 1090 is adjacent to the similar masonry block (see below). (See FIG. 33).

  FIG. 30 is a perspective view generally illustrating one embodiment of a masonry block 1100 in accordance with the present invention. The masonry block 1100 is similar to the masonry block 1030 in FIG. Stretches along the edges. Similarly, the flange 1102 defines a notch 1104 that is substantially parallel to the flange 1102 between the front face 1032 and the back face 1034 along an edge shared with the bottom face 1038. It is growing. The flange 1102 has a height (H5) 1106 and the notch 1104 has a height (H6) 1108. The flange 1102 and the notch 1104 have a width (W3) 1110. In one exemplary embodiment, H5 1106 and H6 1108 are substantially equal to 1.5 times the height of H 1054, and W3 1110 is substantially equal to W1 1062 of retaining wall block 1030 of FIG. Are equal.

  FIG. 31 is a perspective view generally illustrating one embodiment of a masonry block 1120 according to the present invention. The masonry block 1120 is similar to the masonry block 1030 of FIG. 27, but the second end face 1042 has a non-planar shape and is configured to overlap the non-planar end face of a similar masonry block, Or when arranged side by side to form another structure, the masonry block 1120 is adjacent to the similar masonry block (see FIG. 33 below).

  In one embodiment as illustrated in FIG. 31, the second end face 1042 is non-planar and is formed by a flange 1122, which is shared with the bottom face 1038 between the front face 1032 and the back face 1034. Stretches along the edges that are. Similarly, the flange 1122 defines a notch 1124 that extends substantially parallel to the flange 1122 between the front face 1032 and the back face 1034 along an edge shared with the top face 1036. The flange 1122 has a height (H7) 1126 and the notch 1124 has a height (H8) 1128. The flange 1122 and the notch 1124 have a width (W4) 1130. In one exemplary embodiment, H7 1126 and H8 1128 are substantially equal to 1.5 times the height of H 1054, and W4 1130 is substantially the same as W1 1062 of retaining wall block 1030 of FIG. Are equal.

  FIG. 32 is a perspective view generally illustrating one embodiment of a masonry block 1140 according to the present invention, which includes a retaining wall block 1110 of FIG. 30 and a retaining wall block 1120 of FIG. Includes combinations. Accordingly, the first end surface 1040 includes a flange 1102 and a notch 1104, and the second end surface 1042 includes a flange 1122 and a notch 1124, and both the first end surface and the second end surface are similar. When configured to overlap a non-planar end face of a masonry block and arranged side by side to form a wall or other structure, the masonry block 1140 is adjacent to the similar masonry block (see below). (See FIG. 33).

  FIG. 23 is an illustration of a portion of a wall structure 1150 constructed using the gray blocks 1030, 1070, 1090, 1100, 1120, and 1140 of FIGS. 27-32, the gray block comprising at least one non-block. It has a planar end face and is configured to overlap the end face of a similar block according to the invention. As shown, the bonding pattern formed by retaining wall blocks 1030, 1070, 1090, 1100, 1120, and 1140 is illustrated by a pattern formed by a conventional masonry block, for example, FIG. 20A. It is not as grid-like as the wall structure 880.

  34A-34D are simplified views of one implementation of the mold assembly 30 and a block forming process for forming the masonry block 1030 of FIG. The mold assembly 30 includes side members 34a, 34b, cross members 36a, 36b, fixed liner plates 32b, 32c, and movable liner plates 32a, 32d. Each of the drive assemblies 31a and 31b extends the movable liner plates 32a and 32d toward the inside of the mold cavity 46, and contracts the movable liner plates 32a and 32d away from the inside of the mold cavity 46. Combined and configured. Liner faces 100a and 100d are respectively coupled to movable liner plates 32a and 32d. The liner face 100a includes a negative of the flange 1044 and the notch 1046 of the end face 1040, and the liner face 100d includes a negative of the desired three-dimensional texture or pattern that is engraved on the front face 1032 of the retaining wall block 1030 (FIG. 27).

  FIG. 34A is a top view of the mold assembly 30 illustrating movable liner plates 32a and 32d in a retracted position. FIG. 34B is a top view of the mold assembly 30 illustrating the movable liner plates 32a and 32d in the extended position, where the concrete is ready to be introduced into the mold cavity 46. FIG. .

  34C and 34D show a simplified cross-sectional view of mold assembly 30 along section line AA (see FIG. 34A), and a simplified cross-section of mold assembly 30 along section line BB. The figures are shown respectively, and the head shoe assembly 52 and the pallet 56 are further shown. FIG. 34C illustrates the movable liner plate 32d and the corresponding liner face 100d in the retracted position, and the dashed line 1152 indicates the extended position of the liner face 100d. The head shoe assembly 52 further includes a notch 1154 configured to cooperate with the fixed liner plate 32b to form a setback flange 1064 with the back surface 1034 along the edge of the bottom surface 1038 (see FIG. (See FIG. 27).

  FIG. 34D illustrates the fixed liner plate 32c, the movable liner plate 32a in the extended position, and the corresponding liner face 100a. The liner plate 100a cooperates with the head shoe assembly to form a flange 1044 and cooperates with the pallet to form a notch 1046, the notch extending along the first end face 1040 of the retaining wall block 1030 along the front surface. It extends between 1032 and the back 1034 (see FIG. 27).

  While particular embodiments have been illustrated and described herein, it will be understood by those skilled in the art that various alternative and / or equivalent implementations depart from the scope of the present invention. Without particularity, and may be replaced by the specific embodiments shown and described. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.

FIG. 1 is a perspective view of one exemplary embodiment of a mold assembly having a movable liner plate in accordance with the present invention. FIG. 2 is a perspective view of one exemplary embodiment of a gear drive assembly and movable liner plate according to the present invention. FIG. 3A is a top view of the gear drive assembly and movable liner plate, as depicted in FIG. FIG. 3B is a side view of the gear drive assembly and movable liner plate, as depicted in FIG. 4A is a top view of the mold assembly of FIG. 1 with the liner plate contracted. 4B is a top view of the mold assembly of FIG. 1 with the liner plate extended. FIG. 5A depicts a top view of one exemplary embodiment of a gear plate in accordance with the present invention. FIG. 5B depicts an end view of the gear plate depicted by FIG. 5A. FIG. 5C depicts a bottom view of one exemplary embodiment of a gear head according to the present invention. FIG. 5D depicts an end view of the gear head of FIG. 5C. FIG. 6A is a top view of one exemplary embodiment of a gear track according to the present invention. 6B is a side view of the gear track of FIG. 6A. 6C is an end view of the gear track of FIG. 6A. FIG. 7 is a schematic diagram depicting the relationship between a gear track and a gear plate according to the present invention. FIG. 8A is a top view depicting the relationship between an exemplary embodiment of a gear head, gear plate, and gear track in accordance with the present invention. FIG. 8B is an exemplary side view of FIG. 8A. FIG. 8C is an exemplary end view of FIG. 8A. FIG. 9A is a top view depicting one exemplary embodiment of a gear plate in a contracted position within a gear track, in accordance with the present invention. FIG. 9B is a top view depicting one exemplary embodiment of a gear plate present in a position extended from a gear track in accordance with the present invention. FIG. 10A is a schematic diagram depicting one exemplary embodiment of a drive unit according to the present invention. FIG. 10B is a partial top view of the exemplary drive unit of FIG. 10A. FIG. 11A is a top view depicting one exemplary embodiment of a mold assembly in accordance with the present invention. FIG. 11B is a schematic diagram depicting one exemplary embodiment of a gear drive assembly in accordance with the present invention. FIG. 12 is a perspective view depicting a portion of one exemplary embodiment of a mold assembly in accordance with the present invention. FIG. 13 is a perspective view depicting one exemplary embodiment of a gear drive assembly in accordance with the present invention. FIG. 14 is a top view depicting a portion of one exemplary embodiment of a mold assembly and a gear drive assembly in accordance with the present invention. FIG. 15A is a top view depicting a portion of one exemplary embodiment of a gear drive assembly using a stabilizer assembly. 15B is a cross-sectional view of the gear drive assembly of FIG. 15A. 15C is a cross-sectional view of the gear drive assembly of FIG. 15A. FIG. 16 is a side view depicting a portion of one exemplary embodiment of a gear drive assembly and movable liner plate in accordance with the present invention. FIG. 17 is a block diagram depicting one exemplary embodiment of a mold assembly using a control system in accordance with the present invention. FIG. 18A is a top view depicting a portion of one exemplary embodiment of a gear drive assembly using a screw drive system in accordance with the present invention. 18B is a cross-sectional view of the gear drive assembly of FIG. 18A. 18C is a longitudinal cross-sectional view of the gear drive assembly of FIG. 18A. FIG. 19 is a flow diagram depicting one exemplary embodiment of a process for forming a concrete block using a mold assembly in accordance with the present invention. FIG. 20A is a front view generally depicting a portion of one embodiment of a wall structure constructed with conventional masonry blocks. FIG. 20B is a perspective view schematically illustrating an example of a conventional masonry block. FIG. 21 is a perspective view of one embodiment of a masonry block according to the present invention. FIG. 22 is a perspective view of one embodiment of a masonry block according to the present invention. FIG. 23 is a perspective view of one embodiment of a masonry block according to the present invention. FIG. 24 is a perspective view of one embodiment of a masonry block according to the present invention. FIG. 25 is a front view generally depicting a portion of one embodiment of a wall structure constructed by a masonry block according to the present invention. 26A is a top view depicting an exemplary implementation of a mold assembly to form the masonry block of FIG. 26B is a top view depicting an exemplary implementation of a mold assembly to form the masonry block of FIG. FIG. 26C is a partial view of the mold assembly of FIG. 26A. FIG. 26D is a partial view of the mold assembly of FIG. 26B. FIG. 27 is a perspective view of one embodiment of a retaining wall block according to the present invention. FIG. 28 is a perspective view of one embodiment of a retaining wall block according to the present invention. FIG. 29 is a perspective view of one embodiment of a retaining wall block according to the present invention. FIG. 30 is a perspective view of one embodiment of a retaining wall block according to the present invention. FIG. 31 is a perspective view of one embodiment of a retaining wall block according to the present invention. FIG. 32 is a perspective view of one embodiment of a retaining wall block in accordance with the present invention. FIG. 33 is a front view generally depicting a portion of one embodiment of a wall structure constructed by retaining wall blocks in accordance with the present invention. 34A is a top view depicting an exemplary implementation of a mold assembly to form the retaining wall block of FIG. 27. FIG. 34B is a top view depicting an exemplary implementation of a mold assembly to form the retaining wall block of FIG. FIG. 34C is a partial view of the mold assembly of FIG. 34A. FIG. 34D is a partial view of the mold assembly of FIG. 34B.

Claims (21)

A mason reblock molded by a mason reblock machine using a mold assembly, the mold assembly having a plurality of liner plates, at least one of the liner plates being movable. Is
A first lateral surface;
A second lateral surface opposite the first lateral surface;
A first main surface joining the first lateral surface to the second lateral surface;
A second main surface facing the first main surface and joining the first lateral surface to the second lateral surface;
A first end surface joining the first main surface to the second main surface;
A second end face facing the first end face and joining the first main face to the second main face,
The first end surface includes a non-planar surface configured to fit and overlap with a non-planar end surface of a similar masonry block, and through operation of a movable liner plate having a negative of the non-planar end surface. Masonry block, formed during the molding process.   The second end surface includes a non-planar surface configured to fit and overlap a non-planar end surface of a similar masonry block, and through operation of a movable liner plate having a negative of the non-planar end surface. The masonry block of claim 1 formed during the molding process.   At least one of the first main surface and the second main surface includes a desired three-dimensional pattern, and the desired three-dimensional pattern is a negative of the desired three-dimensional pattern. The masonry block of claim 1, engraved during the molding process, through movement of a movable liner plate.   The non-planar surface of the first end surface is formed by a flange, and the flange includes the first main surface and the second main surface along an edge shared with the second lateral surface. The flange defines a substantially parallel notch, the notch extending along the edge shared with the first lateral surface and the first major surface and the second The flange extends between the main surface and the flange is configured to fit into a notch on the end surface of the similar masonry block and to overlap the flange on the end surface of the similar masonry block. Mason re-block as described in.   The second end surface is non-planar and is formed by a flange that extends along the edge shared with the second lateral surface and the first main surface and the second main surface. And the flange defines a substantially parallel notch that extends along the edge shared with the first lateral surface and the second major surface and the second major surface. 5, wherein the flange is configured to fit into a notch on the end face of the similar masonry block and to overlap the flange on the end face of the similar masonry block. Mason reblock as described.   The second end surface is non-planar and is formed by a flange that extends along the edge shared with the first lateral surface and the first main surface and the second main surface. The flange defines a substantially parallel notch, the notch extending along an edge shared with the second lateral surface and the first major surface and the second 5, wherein the flange is configured to fit into a notch on the end face of the similar masonry block and to overlap the flange on the end face of the similar masonry block. Mason reblock as described.   The masonry block according to claim 1, further comprising one or more openings extending through the masonry block from the first lateral surface to the second lateral surface. A retaining wall block molded by a masonry block using a mold assembly, the mold assembly having a plurality of liner plates, at least one of the plurality of liner plates being movable, Wall block
The top surface;
A bottom surface facing the top surface;
A front surface joining the top surface to the bottom surface;
A back surface facing the front surface;
A setback flange extending from the bottom surface along at least a portion of the edge shared with the back surface and formed by movement of a movable shoe assembly during the molding process;
A first side surface joining the front surface and the back surface;
A second side surface facing the first side surface and joining the front surface and the back surface;
At least one of the first side surface and the second side surface includes a non-planar surface configured to fit and overlap a non-planar end surface of a similar retaining wall block, and Retaining wall block formed during the molding process through the movement of a movable liner plate with a planar negative.   The retaining wall block of claim 8, wherein the first side surface and the second side surface are angled, and the width of the front surface is greater than the width of the back surface.   The front includes a desired three-dimensional pattern, and the desired three-dimensional pattern is engraved during a molding process through operation of a movable liner plate having a negative of the desired three-dimensional pattern. Item 9. Retaining wall block according to item 8.   The first side includes a non-planar surface and is formed by a flange that extends between the front surface and the back surface along an edge shared with the bottom surface, the flange being Defining a substantially parallel notch, the notch extending along the shared edge with the top surface between the front surface and the back surface, the flange and notch being negative of the flange and notch The flange is configured to fit into a notch on the end face of a similar masonry block and to overlap the flange on the end face of the similar retaining wall block. The retaining wall block according to claim 8.   The second side includes a non-planar surface and is formed by a flange that extends between the front surface and the back surface along an edge shared with the top surface, the flange being Defining a substantially parallel notch, the notch extending along the shared edge with the bottom surface between the front surface and the back surface, the flange and notch being negative of the flange and notch The flange is configured to fit into a notch on the end face of a similar masonry block and to overlap the flange on the end face of the similar retaining wall block. The retaining wall block according to claim 11.   The first side includes a non-planar surface and is formed by a flange that extends between the front and back along an edge shared with the top surface, the flange being Defining a substantially parallel notch, the notch extending along the shared edge with the bottom surface between the front surface and the back surface, the flange and notch being negative of the flange and notch The flange is configured to fit into a notch on the end face of a similar masonry block and to overlap the flange on the end face of the similar retaining wall block. The retaining wall block according to claim 8.   The second side surface comprises a non-planar surface and is formed by a flange that extends between the front and back surfaces along an edge shared with the bottom surface, the flange being Defining a substantially parallel notch, the notch extending along the shared edge with the top surface between the front surface and the back surface, the flange and notch being negative of the flange and notch The flange is configured to fit into a notch on the end face of a similar masonry block and to overlap the flange on the end face of the similar retaining wall block. The retaining wall block according to claim 13. Generate a masonry block having a first main surface, an opposing second main surface, a first lateral surface, an opposing second lateral surface, a first end surface, and a second end surface A method comprising the steps of:
Providing a mold assembly having a plurality of liner plates, the plurality of liner plates forming a mold cavity having an open top and an open bottom, wherein at least the first liner plate comprises: Being movable between a retracted position and an extended position, the first movable liner plate comprising a desired non-planar surface negative;
Moving the first liner plate to the extended position;
Using a pallet to close the bottom of the mold cavity;
Filling the mold cavity with dry cast concrete through the open top;
Using a shoe assembly to close the top of the mold cavity;
Compressing the dry cast concrete to form a masonry block prior to curing, the first movable liner plate having the first lateral surface resting on the pallet; Forming a desired non-planar surface at one end surface, the desired non-planar surface being configured to fit a non-planar surface of a similar masonry block;
Moving the first liner plate to the contracted position;
Discharging the pre-cured masonry block from the mold cavity;
Curing the masonic reblock prior to curing.   The second liner plate is movable between a retracted position and an extended position, the second liner plate being generally opposite the first liner plate and having a desired non-planar surface. And the method includes stretching the second liner plate subsequent to compressing the dry cast concrete such that a desired non-planar surface is formed at the second end surface. 16. The method of claim 15, comprising moving to a different position, wherein the desired non-planar surface is configured to mate with a non-planar surface of a similar masonry block. .   Compressing the dry cast concrete includes forming a setback flange by providing a notch in the shoe assembly, the setback flange being shared with the second major surface. The method of claim 15, extending from the second lateral surface along an edge.   Compressing the dry cast concrete includes forming one or more hollow cores, the hollow cores passing the masonry blocks from the first lateral surface to the second lateral surface. The method of claim 15, extending through.   The second liner plate is movable between a retracted position and an extended position, the second liner plate including a desired three-dimensional pattern negative, and the method includes a desired non- Moving the second liner plate to the extended position subsequent to compressing the dry cast concrete such that a planar surface is formed in the first major surface. Item 16. The method according to Item 15.   The first movable liner plate forms a desired non-planar surface, the non-planar surface including a flange and a substantially parallel notch, the notch from the first major surface to the second main surface. 16. The main surface of claim 15, wherein the flange is configured to fit into a notch on the end face of a similar masonry block and to overlap a flange on the end face of the same masonry block. Method.   The method of claim 15, wherein the first liner plate is movable between the retracted position and the extended position using a gear drive assembly.

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