MXPA03003409A

MXPA03003409A - Block splitting assembly and method.

Info

Publication number: MXPA03003409A
Application number: MXPA03003409A
Authority: MX
Inventors: Michael J Hogan
Original assignee: Anchor Wall Syst
Priority date: 2000-10-19
Filing date: 2001-10-19
Publication date: 2005-10-18
Also published as: DE60126676D1; AU3969902A; DK1372923T3; EP1372923B8; DE60126676T2; CA2426192A1; NO20031766L; WO2002040235A3; CN1541153A; GB2388337B; WO2002040235A2; NO20031766D0; NZ525872A; GB0311347D0; ATE353746T1; EP1372923A2; AU2002239699B2; GB2388337A; JP2004515380A; AU2002239699A2

Abstract

A masonry block that is produced from a workpiece that is split in a block splitting assembly which uses any of a variety of projections to supplement or replace the action of the splitting blade in splitting and dressing the workpiece. The resulting masonry block has features that provide the masonry block with a weathered appearance.

Description

ASSEMBLY AND METHOD FOR CUTTING BLOCKS RELATED REQUEST This application has been filed as a patent application PCT International in the name of Anchor Wall Systems, Inc., a national corporation of E.U.A. , on October 19, 2001, designating all countries, except the United States.

FIELD OF THE INVENTION The invention relates generally to the manufacture of masonry blocks. More specifically, it relates to equipment and procedures for the creation of decorative faces in a masonry block. Still more specifically, the invention relates to equipment and methods for producing uneven textures and the appearance of weathering or rock-like edges in a masonry block, as well as masonry blocks resulting from said equipment and methods.

BACKGROUND OF THE INVENTION It has become rather common to use concrete masonry blocks for ornamental purposes. Said blocks are used to create, for example, retaining walls, varying from comparatively large structures to fence walls for small trees and garden edge walls. Concrete masonry blocks are made in high-speed production plants, and are typically extremely uniform in appearance. There is no undesirable characteristic in some ornamental applications, but there is a disadvantage in many applications, where there is a demand for a "natural" appearance for the material used to build the walls and other ornamental structures. A way to make concrete masonry blocks less uniform, and more "natural" in appearance, is used in the cutting procedure to create a "rock face" in the block. In this procedure, as commonly practiced, a large concrete workpiece, which has been properly cured, is cut or cracked to form two blocks. The resulting faces of the two resulting blocks along the plane of cut or cracking are textured and irregular, thus they look like "rock type". This method of cutting a work piece into two masonry blocks to create a rock-like appearance on the exposed surfaces of the blocks is shown in, for example, U.S. Patent No. 1, 534,353 to Besser, which describes the cut Manual blocks using a hammer and chisel. Automatic equipment for cutting blocks is well known, and generally includes a cutting apparatus comprising a support table and hydraulically driven, opposing cutting blades. A cutting blade in this application is typically a substantial steel plate that is tapered towards a relatively narrow or sharp blade edge. The blades are typically arranged so that the blade edges will couple the upper and lower surfaces of the workpiece in a perpendicular relationship with those surfaces, and are arranged in a coplanar relationship with each other. During operation, the work piece moves on the support table and between the blades. The blades are brought into engagement with the upper and lower surfaces of the workpiece. An incremental force is exerted on each blade, pushing the blades towards each other. As the forces in the blades are increased, the workpiece is cut (cracked), generally along the plane of alignment of the blades. These machines are useful for high-speed block processing. These produce a rock face finish on the blocks. Neither of the two faces resulting from this procedure are identical, so that the blocks are more natural in appearance than the uncut, standard blocks. However, the edges of the faces resulting from the standard industrial cutting process are generally well defined, ie they are regular and "sharp or sharp", and the uncut surfaces of the blocks, which sometimes in view of applications ornamental, they are regular, "bright" and non-textured, and have a "machine-made" appearance.

These concrete masonry blocks can be made to have a more natural appearance if the regular, sharp edges of their faces are removed. A known procedure for removing regular, sharp edges on concrete blocks is the procedure known as tamboreación (cleaning of pieces by stirring in a drum). In this procedure, a relatively large number of blocks is loaded onto a drum, which is rotated about a generally horizontal axis. The blocks collide violently against each other, hitting the sharp edges, and also crushing and opening deeply the edges and faces of the blocks. The procedure has been commonly used to produce a "used" appearance, of wear and tear on concrete paving stones. These paving stones are typically relatively small blocks of concrete. A common size is 9,525 cm wide by 19.68 cm long by 6.35 cm thick, weighing approximately 2,724 kilograms. The drumming process has also now been used with some retaining wall blocks to produce a less uniform, weather-worn appearance for the faces of the blocks. There are several disadvantages in the use of the drumming procedure in general, and in particular to the tumbling of retaining wall blocks. In general, the drumming procedure is a very expensive procedure.

The blocks must be very strong before they can be shaken. Typically, blocks must settle for several weeks after they have been formed to gain adequate strength. This means that they must be assembled in cubes, typically on wooden pallets, and transported from the production line during the necessary storage time. They can then be transported to the rotating drum, removed from the pallets, processed through the rotating drum, formed into cubes and re-formed into pallets. All this "offline" processing is expensive. In addition, there can be a substantial deterioration of the blocks that break in the rotating drum. The tamboreación device by itself can be very expensive, and a high maintenance item. The retaining wall blocks, unlike the pavers, can have relatively complex shapes. These are stacked in sections during use, each section receding a uniform distance from the bottom section. The retaining walls should also typically have some shear strength between the sections, to resist the pressures of the earth below the wall. A common way to provide uniform retraction and shear strength from section to section is to form an integral locator / shear stress key on the blocks. Commonly, these keys have the shape of lips (lashes) or tongue and groove structures. Since the retaining wall blocks vary in size from absolutely small blocks (eg, from approximately 4.54 kilograms and having a front face with an area of approximately 0.0232 m2) to blocks that are too large that have a front face of .0929 m2 and weighing 45.4 kg, they can also be hollowed out or have extended tail sections. These complex forms can not survive the tambo reaction procedure. The locators are hit, and the protections of the faces are cracked. As a consequence, the revolving retention wall blocks are typically of very simple, relatively small shapes, and do not have integral locator / shear stresses. Rather, they should be used with auxiliary pins, fasteners, or other devices to establish recoil and shear strength. The use of these pins or auxiliary fasteners makes the construction of walls more difficult and expensive than in the case of blocks that have integral locators. Another option to remove regular edges, sharp and to remove the tension of the face of the concrete blocks, is to use a machine type mill with hammers. In this type of machine, rotating hammers or other tools attack the face of the block to chip pieces of it. These types of machines are typically expensive, and require space in the production line that is usually not available in block plants, especially very old plants. This option can also reduce production, if done "online", since the procedure can only move the hammer mill as quickly as possible so that it can operate in each block, and the blocks typically need to be manipulated, for example, twisted and / or rotated, to attack all its edges. If the hammer mill type process is carried out offline, it creates many of the inefficiencies described above with respect to drumming. Accordingly, there is a need for equipment and a procedure that creates a more natural appearance to the faces of concrete retaining wall blocks, inter alia, by eliminating the sharp, regular face edges resulting from the standard industrial cutting process. , in particular, in such a way that it does not reduce the production line, does not add very expensive equipment to the line, does not require additional space in a production line, is not heavy work, and does not have high classification speeds when they process blocks with integral locating tabs or other similar characteristics.

COMPENDIUM OF THE INVENTION According to a first aspect of the invention, a masonry block is provided which results from a cutting operation in a work piece molded through at least one cutting assembly in a block cutter having a cutting line. At least the cutting assembly includes a plurality of projections disposed on at least one side of the cutting line and positioned to engage the work piece during the cutting operation. The resulting masonry block comprises a block body including an upper surface, a lower surface, a front surfaces extending from the upper and lower surface, a rear surface extending from the upper and lower surfaces, lateral surfaces between the front and rear surfaces. In addition, the block includes a locating protrusion formed integrally with the block and disposed on the upper or lower surfaces thereof. The intersection of the front surfaces and the top surfaces defines an upper edge, and the intersection of the front surface and the bottom surface defines a lower edge, and the front surface and at least a portion of one of the upper edge and the lower edge they are irregular as a result of the plurality of projections that couple the work piece during the cutting operation. In the preferred embodiment, the locating protrusion is preferably disposed on the lower surface. The irregular edge portion of the block is depressed so that it does not appear as a tip with regular, well-defined edges, but rather appears as worn out by time, ruffled or otherwise broken, irregular and worn. According to a second aspect of the invention, a wall is provided which is formed from a plurality of masonry blocks.

According to another aspect of the invention, a masonry block formed of a molded work piece is provided. The masonry block comprises a block body including an upper surface, a lower surface, a front surface extending between the upper and lower surfaces, a rear surface extending between the upper and lower surfaces, and lateral surfaces between the front and rear surfaces . A portion of at least one of the surfaces is textured as a result of at least one channel provided in a wall of the workpiece forming mold. In another aspect of the invention, a masonry block is provided which is produced from a molded work piece that is cut into a block cutter having a cut line. The block cutter comprises a first cutting assembly that includes a plurality of projections disposed on at least one side of the cutting line. The projections are positioned so as to couple the work piece during the cutting operation, whereby the masonry block includes at least one irregular edge and cutting surface produced by the first cutting assembly. According to another aspect of the invention, there is provided a method for producing a masonry block having at least one irregular edge and cutting surface. The method comprises providing a masonry block cutter having a cut line with which a pole workpiece that will be cut will be aligned, the block cutter including a first cut assembly including a plurality of projections arranged on at least one side of the cutting line. The projections are positioned so that they couple the work piece during the cutting operation. A masonry work piece is located in the masonry block cutter so that the work piece is aligned with the cutting line, and the work piece is cut into at least two pieces using the cutting assembly. In another aspect of the invention, a masonry block is provided having at least one edge and an irregular cutting surface that occurs when a molded workpiece is cut into a block cutter comprising a first cutter blade assembly having a first cutter blade connected to a first blade holder. The first blade support includes a blade support surface extending from the first cutting blade on at least one side thereof. The blade support surface is arranged at an acute angle relative to the horizontal, and the blade support surface can be engaged with the workpiece during the cutting operation. The irregular edge and cutting surface are at least partially the result of the contact of the blade support surface with the workpiece. In still another aspect of the invention, a cutting assembly for use in a block cutter is provided. The block assembly comprises a cutting blade, and a plurality of projections positioned adjacent to the cutting blade on at least one side thereof. The projections and the blade are fixed relative to one another during a cutting operation whereby the projections and the blade move simultaneously during the cutting operation. In still another aspect of the invention, a mold for producing at least one masonry unit with a texture on at least one surface is characterized by a plurality of side walls defining a mold cavity open at its top and bottom for to allow the introduction of masonry filling material into the mold cavity through its open top and to discharge the molded filler material in the form of a masonry unit molded through its open bottom. At least one surface texturizing channel is formed in the face of at least one of the side walls of the mold, the channel extending through the face of the side wall in a direction not parallel to the cutting direction of the mold . The channel has a height of at least about 1.90 cm and a depth of less than about 1.27 cm, and at least a portion of the channel is separated from the top of the wall where it is formed through a distance that is greater than about 40% of the distance from the top of the side wall to the bottom of the side wall. In addition, a ratio of the total projected area of the side wall provided with the channel to the total projected area of all the channels is greater than about 2: 1. In still another aspect of the invention, a masonry block cutter is provided having a cutting line with which a work piece is aligned to cut the work piece into at least two pieces. The block cutter comprises a first block assembly that includes a plurality of projections disposed on at least one side of the cut line. The projections are positioned so that they travel towards the work piece as it is cut into at least two pieces by the block cutter, whereby the first cutting assembly contributes to the formation of at least one edge and one uneven cutting surface on at least one of the cut pieces. These and other various advantages and aspects of novelty characterizing the invention are pointed out with particularity in the appended claims and which form a part thereof. However, for a better understanding of the invention, its advantages and objects obtained through its use, reference should be made to the annexed drawings that form an additional part thereof, and to the accompanying description, wherein a modality is described. preferred of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a partial perspective view of a block cutting machine using the block cutter assembly of the invention. Figure 2A is a top plan view of a portion of a cutting blade assembly according to the invention. Figure 2B is a top plan view of a portion of a cutting blade assembly also showing projections of various diameters placed in a random manner. Figure 2C is a top plan view of a portion of a cutting blade assembly according to a further alternative embodiment of the invention, comprising projections that are panels connected and disconnected in a random manner. Figure 3 is a side elevational view of an alternative embodiment of a projection according to the invention. Figure 4A is a side elevational view of a further alternative embodiment of a projection according to the invention. Figure 4B is a side elevational view of another alternative embodiment of the invention illustrating projections of varying heights. Figure 5 is a perspective view of a cut piece of work (forming two blocks of masonry), which was cut using a cutter blade assembly of the invention.

Figure 6 is a top plan view of a masonry block cut using the cutter blade assembly of the invention. Figure 7 is a front elevational view of the masonry block illustrated in Figure 6. Figure 8 is a partially sectioned end view of an alternative embodiment of an upper cutter blade assembly. Figure 9 is a partially sectioned end view of an alternative embodiment of a lower cutting blade assembly. Figure 10 is a top plan view of a lower cutting blade assembly portion of Figure 9 with a projection arrangement, shown in relation to a workpiece. Figure 1 1 is a partially sectioned end view of another alternative embodiment of a lower cutting blade assembly. Figure 12 is a top plan view of a fastener assembly according to the present invention and a portion of the lower cutter blade assembly of Figure 11 with another projection arrangement shown relative to a workpiece. Figure 12A is an exploded view of the portion contained within line 12A in Figure 12.

Figure 13 is a top plan view of a mold assembly for forming the work piece illustrated in Figure 12. Figure 14 is a perspective view of a masonry block that is cut from a workpiece using upper and lower cutting blade assemblies of the type illustrated in Figures 8 and 11. Figure 15 is a bottom plan view of the masonry block of Figure 14. Figure 16 is a side view of the masonry block of Figure 14. Figure 17 is a perspective view of an alternative embodiment of a block of masonry that has been cut according to the present invention. Figure 18 illustrates a wall constructed from blocks with different sizes that have been cut according to the invention. Figure 19 is a front view of a mold wall where an individual horizontal groove or channel has been cut into the wall near the bottom of the wall. Figure 20 is a sectional view of the mold wall shown in Figure 19 taken on line 20-20 to show the cross section of the slot. Figure 21 is a top view of a hopper and partition plate for stirring the colors of the filling material. Figure 22 is a front view of a mold wall wherein multiple hollow diagonal grooves or channels have been cut into the wall at an angle to the horizontal. Figure 22A is a sectional view of the mold wall shown in Figure 22 taken on line 22A-22A to show the cross section of the grooves. Figure 23 is a front view of a mold wall where an individual horizontal groove or channel has been cut into the wall near the bottom of the wall. Figure 23A is a sectional view of the mold wall shown in Figure 23 taken on line 23A-23A to show the cross section of the slot. Figure 24 is a front view of a mold wall where multiple slots or diagonal channels have been cut, holes in the wall at an angle to the horizontal of approximately 45 degrees to provide a "crossover" pattern. Figure 25 is a sectional view of a mold wall showing the cross section of the multiple horizontal grooves or channels cut in the mold wall, extending near the bottom of the mold wall towards the top of the mold wall. Figure 26 is a sectional view of a mold wall showing the cross section of a v-shaped groove. Figure 27 is a front view of a wall of a mold where a serpentine groove or channel has been cut.

DETAILED DESCRIPTION OF THE PREFERRED MODALITY Now attention is drawn to the drawings where similar parts are identified with similar numbers through the various views. In Figure 1, a modified conventional block cutting machine according to the invention is illustrated, in part showing in particular the block cutter assembly 10. In general, block cutters suitable for practicing the present invention can be obtained from Lithibar Co., located in Holland, Michigan and other equipment manufacturers. In particular, the Lithibar Co., model 6386 was used to practice the invention. The block cutter assembly 10 generally comprises a support table 11 and first and second opposing cutting knife assemblies, 12 and 22. The first cutting blade assembly 12 is placed at the bottom of the block cutter 10 and, as illustrated, it includes a cutting blade 14 projecting from a blade holder 15 and a number of projections 16 placed on the blade holder 15 on both sides of and adjacent to the blade. In this case, the projections 16 are generally pieces of steel with cylindrical shape, having distant round or bullet-shaped ends. The first cutting blade assembly 12 is adapted to be moved up through an opening in the support table 1 1 to engage the work piece 40, and to move down through the opening so that a Subsequent work piece can be placed in the cut. The invention can also be used with any variety of blocks molded or formed through any variety of processes, including those blocks and methods described in U.S. Patent No. 5,827,015 issued October 27, 1998, U.S. Patent No. 5,017,049 issued on May 21, 1991, and US Patent No. 5, 709,062 issued January 20, 1998. Figure 1 also shows an upper or second cutter blade assembly, 22. The second blade assembly Cutting 22 also includes a cutting blade 24 and a plurality of projections 26 located on both sides of the blade 24. The second cutting blade assembly can be attached to the upper plate 30 of the machine through a blade holder 28. The position of the work piece 40 (shown in faded lines), inside the block cutter can be seen in Figure 1, in the ready to cut position. As can be seen in Figure 2A, the cutting blade assembly 12 is generally composed of a number of projections 16 placed adjacent the blade 14 and on either side of the blade 14. As shown, the projections 16 on the first side of the blade are staggered in relation to the projections 16 'on the second side of the blade. The projections on either side of the blade can also be aligned depending on the operator's intent.

As can be seen in Figure 2B, the projections 16 can be used without a cutting blade. The projections 16 can also have a varied diameter or perimeter (if they are not round), and be placed randomly on the cutting assembly 12. Any number of ordered or random patterns of projections 16 can be created using a regular or irregular space, depending on the effect that will be created in the cut block. Figure 2C shows a further alternative embodiment of the invention, wherein the plates 16"are attached to either, or both assemblies 12 and 22. As can be seen, these plates can be configured in random order and be left without connection through the surfaces of the assembly 12. The invention has been practiced using steel plates with a length of approximately 10.16 cm, welded to the assembly to provide a number of projections 16"partially connected with a height of approximately 5.08 cm. In cutting assemblies where cutting blades are used, such as the cutting blades 14-24, the cutting blades are arranged in a coplanar relationship, and in order to couple the lower and upper surfaces of the workpiece 40 in a generally perpendicular relationship. The cutting blade 14 (and likewise the cutting blade 24) defines a cutting line SL, shown in Figure 2A, with which the work piece 40 is aligned to cut. When the cutting blades are not used, as shown in Figure 2B, the workpiece 40 remains aligned with the cutting line SL, which is illustrated extending generally through the center of the assembly 12. In any case, block cutters conventionally have a cutting line SL, defined by cutting blades when used, with which the work piece is aligned for cutting. As shown in Figures 1, 2A and 2B, the projections 16 and 16 'may have a round shape. However, the shape of the projections can also be pyramid, cubic, or pointed with one or more points on the upper surface of the projection. In Figures 2A, 2B and 2C, the relative position of the workpiece 40 is again shown in a profile in faded lines. In general, the projections may have a diameter of about 1.27 to about 3.17 cm and may be attached to the blade assembly through welding, screws or other suitable means. The height of the projections can be approximately 3.17 cm and varied to approximately 1.90 cm 1 cm shorter or longer depending on the effect that will be created in the block at the time of cutting. The connection of the projections through threads or screws, see Figures 8-9 and 11, allows easy adjustment of the height of the projection. The relative height of the projection and the blade may also vary depending on the effect that is to be created on the block that is being cut from a workpiece according to the invention. Specifically, as seen in Figure 3, the relative height of the blade 14 may be less than the relative height of the projection 16. Alternatively, as can be seen in Figure 4A, the relative height of the blade 24 may be greater. that the height of the projections 26. For example, it has been found that the first cutting blade assembly 12 that X can vary from about 0.31 to about 0.95 cm below or behind the first blade 14. With respect to the second assembly of cutting blade 22, X 'may vary from about 0.15 to about 0.31 of 1 cm more than the height of the plurality of projections 26. Projections 16 such as those illustrated in Figure 2A have been found to be useful in having a diameter of approximately 2.54 cm and 0.635 cm and, when used with the blade 14, have a height of approximately 0.31 of 1 cm below the blade in the first or lower assembly 12 and approximately 0.31 of 1 cm below the blade 24 in the second or upper assembly 22. In summary, the height of the projections in both the lower assembly 12 and the upper assembly 22 may vary upwards or downwards as much as approximately 0.95. of 1 cm in relation to the height of the blade in any direction relative to the top of the blade with the top of the blade being zero. During operation, the workpiece is generally centered on the block cutter and aligned with the cutting line SL according to the known practices as seen in Figures 1, 2A, B and C. The block cutter is then activated resulting in the first and second opposed cutting blade assemblies 12, 22 converging, and striking the workpiece 40. During operation, the first and second cutting blade assemblies can travel anywhere from about 0.635 to about 2.54. cm towards the upper and lower surface of the workpiece. The workpiece 40 is then cut resulting in an uneven or irregular pattern on the cut edges 46a, 46b and 46a1, 46b 'of the respective blocks 42 and 44, as illustrated in Figure 5. As illustrated, the workpiece 40 is cut in two. However, it is possible and within the scope of the invention to cut the workpiece into more than two pieces. It is also possible and within the scope of the invention to cut the workpiece into a useful masonry block and a piece of waste. The distance traveled by the projections 16, 26 towards the work piece can be varied by adjusting the limit switches on the block cutting machine and, at the same time, by varying the hydraulic pressure with which the cutting assemblies act. In general, the cutting assemblies act on the block with a pressure ranging from about 42.18 to about 70.3 kg / cm2, and preferably from about 52.72 to about 56.24 kg / cm2. As will be understood by one skilled in the art, the cutting machine may include opposed hydraulically activated side blade assemblies (not shown), which strike the block at the same time and in the same manner as the upper and lower assemblies. opposite. The projections 16, 26 can also be used to supplement or replace the action of the side knives, as discussed below with respect to Fig. 12. For example, side knives similar to the upper cutter 24 shown in FIG. Figure 8. The closest examination of block 44 after cutting (see Figure 6 and 7) shows the formation of exaggerated points of elusion on the cut, irregular front surface 47 of block 44. With block 44 illustrated, both the first and second blade assemblies 12 and 22 comprise projections 16 and 26, respectively. As a result, depressions 48 and 50 are formed at the upper and lower edges 46a, 46b of the cut, front surface 47 of the block 44, at the intersection with the respective upper surface 52 and lower 54 of block 44. The magnitude of the indentations , 48 and 50, or points of erosion is much greater than that which is caused by conventional cutting blades and can be varied by varying the prominence of projections 16 and 26 (height and size), in relation to height and thickness of the blade. In one embodiment of the invention, the masonry block can be cut with only one row or rows of projections 16 and 26 without a blade 14 and 24.

Returning to FIGS. 8 and 9, alternative embodiments of an upper cutter assembly 22 'and a lower cutter assembly 12', respectively, are shown. It has been found that more massive blade assemblies 12 ', 22', having projections 16, 26, include blade supports 15 ', 28' having blades 14 ', 24' including central cutting edges 21, 31, respectively. The blade supports 15 ', 28', include surfaces 19, 29 that extend outwardly from the blades 14 ', 24'. The cutting edges 21, 31 define the cutting line along which the workpiece will be cut. The surfaces 19, 29 extend from the blades 14 ', 24' at relatively shallow angles, so that, as the blade assemblies converge during the cutting, the surfaces 19, 29 will engage the cut edges of the work piece. job. This coupling breaks, crumbles, crushes or softens the cut edges into an irregular shape, and the depletion action can be improved by placing the projections on the surfaces 19, 29, as desired. The surfaces 19, 29 are preferably at an angle a of between about 0 ° and about 30 ° with the relation to the horizontal, most preferably about 23 °.

The blade assemblies 12 ', 22' include projections 16, 26 that are adjustable and removable. In this way, the same blade assembly can be used to cut different block configurations by changing the number, location, spacing and height of the projections. Projections 16, 26 are preferably threaded into corresponding threaded openings 17, 27 for adjustment, although other height adjustment means may be employed. However, during a cutting action, the projections, the blades and the blade supports are fixed relative to each other, whereby the blade holder moves the projections associated with the blade and the blade holder moves. simultaneously with them. The projections 16, 26 in this embodiment are preferably made of a pointed metallic carbide material. In addition, the upper surface of the projections 16, 26 is toothed, comprising many pyramids in a checkerboard image pattern. You can get projections such as these from Fairlane Products Co. of Frase, Michigan. It will be understood that a variety of other top surface projection configurations may be employed. The height of the upper surface of the projections is preferably a distance X 'below the cutting edge 21, 31 of the blades 14', 24 ', most preferably 0.1016 cm below. As discussed above with respect to other embodiments, the projections may extend below, or some distance above, the top of the blade, within the principles of the invention. The projections shown have a diameter of approximately 1.90 cm with a pitch of 10 threads / 2.54 cm, and a length of approximately 3.81 cm. It is believed that diameters of between about 1.27 and about 2.54 cm are preferred. The loose block material of the cutting process entering the threads, in combination with the vertical force of the cutting strokes, is considered sufficient to lock the projections in place. However, other mechanisms may be used to lock the projections in place relative to the blades during the cutting procedure. As will be apparent from the description, the blades 14 ', 24' and the projections 16, 26 are locations of wear during the cutting process. The removable assembly of the projections 16, 26 allows the projections to be removed and replaced as necessary due to such wear. It is also preferred that the blades 14 ', 24' are removable and replaceable, so that as the blades wear out, they can be replaced as needed. The blades 14 ', 24' can be secured to the respective blade supports 15 ', 28' through any number of conventional removable fastening techniques, such as bolting the blades to the blade supports, each blade being removably arranged within a slot 25 formed in the respective blade holder as shown in Figure 1 1 for the blade 14 '. The preferred upper blade assembly 22 'has a width of approximately 6.35 cm as measured between the side walls 28a, 28b of the blade holder 28'. The projections 26 extend perpendicularly from the surfaces 29 and thus strike the workpiece at an angle.

The preferred lower blade assembly 12 'has a width of approximately 10.16 cm as measured between the side walls 15a, 15b of the blade holder 15'. The projections 16 extend upwards from the shoulders 23 on the opposite sides of the surface 19. This configuration breaks more material and creates an upper edge of the rounder rock type of the resulting cut block (the work piece is typically inverted or "mouth up" which allows the workpiece to remain flat on what will be the upper surface of the resulting block (s) The preferred lower blade assembly 12 'also includes adjustable and removable projections 16 extending upward from the surfaces 19, as shown in Figures 1 1 and 12. In this case, the projections 16 extend perpendicular to the surface 19 and collide with the workpiece at an angle, the projections 16 extending upwards from the surfaces 19 and the projections extending upwardly from the shoulders 23 may be of different sizes as shown in Figure 1 1, or of the same size or as shown in Figure 12. The deflection of the projections 16 on the surfaces 19 of the blade holder 15 'and the deflection of the projections 16 on the surfaces 29 of the blade holder 29', allow the projections 16, 26 penetrate the work piece and break the material mainly adjacent to the upper and lower edges of the resulting block, however, without breaking too much material.

As will be discussed later in greater detail with respect to Figure 12, the lower blade assembly typically makes contact with the workpiece after the upper blade assembly has started its cutting action. The initial cutting action of the upper knife assembly can force the cut pieces resulting from the workpiece to separate from each other before the lower knife assembly 12 'and the angled projections 16 can fully complete their cutting action . The vertical projections 16 on the surfaces 23 of the blade holder 15 'help to keep the cut pieces in place to allow the angled projections 16 to complete their cutting action. The vertical projections 16 also break portions of the cut pieces adjacent to the bottom edges of the resulting block (s). In this manner, the angled and vertical projections 16 on the lower knife holder 15 'function together to produce a round bottom edge on the resulting block, while the angled projections 26 on the knife holder 28' function to produce an edge top round of the resulting block. During operation, knife assemblies 8 and 11 are preferably used together to cut a workpiece, using the same depth of cut and hydraulic pressures described above. It will be understood that the lower blade assembly can be used on the upper part, and the upper blade assembly can be used on the bottom.

Referring now to Figure 10, there is illustrated a blade assembly 12 'according to Figure 9, in a position to collide against a workpiece 58. The workpiece 58 comprises portions that will result in small blocks 60, medium 62 and large 64. The projections 16 are preferably placed in appropriate locations on the blade holder 15 'to create the three blocks 60, 62, 64 when the workpiece 58 is cut. For example, the projections 16 can be located as shown in Figure 10. The upper knife assembly of Figure 8, which can be used in conjunction with the knife assembly of Figure 9 to cut the workpiece 58, has similarly oriented projections, except that they are closer to the SL cut line defined by the cut edge 31. In this way, more rounded rock-like edges are formed on the masonry blocks resulting in the cutting process. The position of the projections on the blade supports 15 ', 28' can be used in conjunction with mold configurations that pre-form the workpiece 58 at predetermined locations to better achieve having rock-like, round corners. For example, the mold walls that are used to form the workpiece 58 in Figure 10 may include suitable contoured portions, in order to form the contoured regions 59a, 59b, 59c on the workpiece 58. The contoured regions 59a, 59b, 59c contribute to the formation of the round rock-like corners, when the workpiece 58 is cut. Additional information on the mold configuration that is used to create the work piece 58 can be found in the co-pending US patent application No. 09/691, 931, filed on October 19, 2000, which is incorporated herein by reference. by reference in its entirety. Referring now to Figure 12, a fastener assembly 70 is shown together with a preferred workpiece 68 for use in forming a pair of blocks in accordance with the present invention. A lower cutter blade assembly 12 'according to FIG. 1 1, which is preferably used, in combination with the upper cutter assembly of FIG. 8 to cut the workpiece 68, is also shown in relation to FIG. to workpiece 68. Figure 12A illustrates the portion contained within line 12A in Figure 12, in greater detail. The workpiece 68 is illustrated in faded lines for clarity. The fastener assembly 70 is employed to assist in the cutting of certain types of larger block units. It is mounted through the mounting head 71 on the existing side cutter cylinders of the cutting machine. Rubber shoes 72 are configured to conform to the external surface corresponding to the workpiece 68. Each fastener assembly 70 moves in and out laterally, as indicated by the arrows, in order to hold the workpiece 68 from both sides. In the preferred design, the assembly 70 has a height of approximately 6.45 cm and the rubber shoes 72 have a hardness of 50-100 durometers. The pressure applied by the hydraulic cylinders is equal to that for the upper and lower blades. A benefit of this fastener assembly is to improve the formation of round edges of a workpiece made through a lower cutting blade assembly. A workpiece 68 moves along the manufacturing line by placing the bar 80 in the direction of the arrow shown. During cutting, while the back portion of the workpiece 68 is held in place by the bar 80, the front portion is free to move forward. Many cutting machines have a cutting action whereby the lower blade assembly moves to engage the workpiece after the upper blade assembly has touched the top of the workpiece. Initial cutting action of the upper knife assembly can begin to move the forward portion forward before the lower knife assembly has the opportunity to fully form a round edge on the front block with, for example, projections 16 and / or surfaces 19. The lower blade assembly can also raise the workpiece 68, which is undesirable for a number of reasons. By keeping the workpiece 68 together during cutting, these problems are avoided. Fastener assembly 70 may optionally include projections 16, as shown in Figures 12 and 12A. The projections 16 are preferably placed slightly within the upper and lower edges of the workpiece 68 (four projections for each fastener assembly 70), so that when they collide against the side of the workpiece-68, more round block corners will be formed. The assembly 70 may also include a side blade contained within its central cavity 73, having a blunt blade such as that described above, to form rock-like, round side edges of the cut blocks. It may be necessary to include an appropriate resistance spring behind the side blade in order to obtain the desired action of the fastener and the blade. The preferred workpiece 68 is also formed to include contoured regions 74, 75, 76, 77 at predetermined locations to achieve better round rock-like corners. For example, the mold walls that are used to form the workpiece 68 in Figure 12 may include a suitable contour formation in order to form the contoured regions 74-77 in the workpiece 68 (see Figure 13) . The contoured regions 74-77 contribute to the formation of round, rock-like corners when the workpiece 68 is cut. The contoured regions 74-77 preferably extend over the entire height of the workpiece from the lower surface towards the upper surface thereof. The contoured regions 74, 75 are best seen in Figure 12A. It should be understood that the contoured regions 76, 77 are identical to the regions 74, 75 but are located on the opposite side of the workpiece 68. The contoured regions each include a convex section 78 having a radius R and a linear section 79 moving toward the lateral surface of the workpiece 68. The shape of the contoured regions is selected to obtain corners with satisfactory radius on the block once the workpiece 68 is cut. Satisfactory results have been achieved using a radius R of about 2.54 cm, a distance d - between the intersection of the convex section 78 with the linear section 79 and the edge of the projection 16 of about 0.635 cm, a distance di between the intersection of the convex section 78 with the linear section 79 and the center of the projection 16 of approximately 1.43 cm, and a distance d3 between the closest points of the convex sections 74, 75 of approximately 1.71 cm. Other dimensions can be used depending on the final results sought. Figure 13 illustrates a mold 84 that is used to form the workpiece 68. The mold 84 is provided with two mold cavities 86a, 86b to allow the simultaneous formation of a pair of workpieces 68 and finally four blocks. Other configurations can also be used to produce a greater or lesser number of workpieces. The mold walls 84 in each mold cavity include regions 88-91 that are configured to produce the contoured regions 74-77, respectively, on the workpiece 68. A masonry block 100 that results from a cutting procedure in the workpiece 68 using the cutting assemblies 12 'and 22' of Figures 1 1 and 8, respectively, is shown in Figures 14-16. The masonry block 100 includes a block body with a generally flat upper surface 102, a generally flat lower surface 104, side surfaces 106, 108, a front surfaces 1 10 and a rear surface 1 12. The words "upper" e " "lower" refer to the surfaces 102, 104 of the block after cutting and after the block is inverted from its lip orientation upwards during cutting. In addition, the front surface 1 10 of the block 100 is connected to the side surfaces 106, 108 through the rounded sections 114, 1 16. The rounded sections 1 14, 1 16 have a radius of about 2.54 cm as a result of the regions contoured 74-77 on the work piece. In addition, due to the position of the projections 16 on the blade assembly 12 'shown in Figure 12, and the similar position of the projections 26 on the blade assembly 22 ', the upper left and right corners and the lower left and right corners of the block 100 in the rounded sections 1 14, 1 16 are removed during the cutting process. The rounded sections 1 14, 1 16 serve several purposes, first of all, they present a natural appearance, more rounded to the block, as compared to a block where the front face crosses the sides at an acute angle. Secondly, in the case of the sharply angled block, the cutting / depressing action produced by the cutting blade assemblies described herein can break large sections of the corners, which can create reasonably important gaps in the walls. In general, contact between adjacent blocks in a wall is sought in order to act as a block for the filling material, such as earth, which can be swept through the wall, as well as to eliminate gaps between adjacent blocks, which is generally believed to diminish the appearance of the wall. If proper precautions are not used, such as placing a filter cloth behind the wall, fine dirt behind the wall will eventually pass through the wall. The use of the rounded section 1 14, 1 16 seems to minimize the corner break to an acceptable degree, in order to preserve better contact or stop surfaces with adjacent blocks in the same stretch when the blocks are stacked to form a wall.

In the blocks of Figures 14-16, the upper and lower surfaces 102, 104 do not have to be completely planar, but rather have to be configured such that, when stretched in sections, the upper surfaces and bottoms of the block in adjacent stretches they remain generally parallel to each other. In addition, the front face 1 10 of each block is wider than the rear face 1 12, which is achieved through the convergence of at least one of the side surfaces 106, 108, preferably both side surfaces, towards the surface back This construction allows the construction of internal radio walls.

It is also contemplated that the side surfaces 106, 108 may begin convergence, starting from a separate position from the front surface 1 10. This allows the adjacent blocks to abut slightly behind the front face, which in turn means that they exist less chance that fine materials behind the door can enter through the face of the wall. Said block shape is shown in Figure 17. The front surface 10 of the block has a rock-like, irregular texture. In addition, an upper edge 18 and a lower edge 120 of the front surface 10 are also irregular as a result of the projections 16, 26 on the cutting blade assemblies 12 ', 22'. As a result, the front surface 1 1 0 of the edges 1, 18, 120 are provided with a rocky, irregular appearance. In addition, the entire front surface 10 is slightly rounded from the top to the bottom when viewed from the side. The edges 18, 120 are also rounded. Figures 14 and 16 also illustrate the rounded sections 1 14, 16 and at least a portion of the side surfaces 106, 108 being slightly textured. The light texturing is achieved by using a horizontal groove or channel that forms in the mold walls at the locations where a slight texturing is desired on the workpiece and the resulting block.

Figure 19 illustrates a portion of a mold wall 1 17 of the mold 84 in Figure 13, which has a generally horizontal channel or groove 1 19 provided in the wall near the bottom of the wall. Figure 20 is a cross-sectional view of the wall 1 17 showing the shape of the channel 1 19. The mold wall 1 17 corresponds to a surface of the block that is slightly textured, such as the side surface 106. The channel 1 19 Illustrated is extended along a portion of the wall 17, in which case slight texturing will occur from only a portion of the corresponding surface of the workpiece. However, the channel 1 1 9 can extend along the entire length of the wall 1 17 if light texturing is desired along the entire corresponding surface. Channel 1 19 is illustrated in rectangular shape in cross section. However, other shapes may be used such as semicircular (see Figures 23 and 23A), v-shaped (see Figure 26), or ear-shaped, and multiple slots or channels may be used (see Figures 22, 22A, 24 and 25). These multiple slots or channels may be of the same or different heights in the mold wall. The channels can generally be parallel to the bottom of the mold (see Figure 25) or they can be oblique (see Figure 22) or even non-linear such as a coil (see Figure 27). Cross patterns can be used (see Figure 24). The slot (s) may extend partially or completely through the mold wall. For reasons not currently understood, some of the channel patterns (for example, cross patterns) tend to be repeated or mirror images on the surface of finished masonry units, which produces interesting visual effects when the masonry units are assembled on a wall or other structure. The channel 1 19 in Figures 19 and 20 preferably has a height of approximately 1.27 cm, a depth of approximately 0.1524 cm, and channel 1 19 starts from approximately 0.2286 cm from the bottom of wall 1 17. Other channel dimensions, in addition to channel shapes, can be used with variations in the resulting light texturing that is produces. For example, Figure 22 is a front view of a mold wall 200 where multiple hollow diagonal grooves or channels in the wall have been cut at an angle to the horizontal of about 30 degrees. With reference to Figure 22A, a typical size for the channels is a width G of approximately 0.635 cm, a depth D of approximately 0.0762 cm, and an S space of approximately 0.635 cm between channels. Alternatively, the slots or channels may be cut into the wall at an angle to the horizontal of about 45 degrees, and may have a width G of about 1.27 cm, a depth D of about 0.0762 cm, and a separation S of about 1 .27 cm Figure 22A is a sectional view of the mold wall 100 shown in Figure 22 illustrating the rectangular, hollow cross section of the grooves. Figure 23 is a front view of the mold wall 200, where a single horizontal slot or channel has been cut into the wall near the bottom of the wall. A suitable size for the channel, which is semicircular in cross section, can be a diameter of approximately 0.9525 cm (dimension G in Figure 23A) and the channel is within approximately 0.254 cm from the bottom of the wall. Alternatively, the channel may be rectangular in cross section. Figure 24 is a front view of the mold wall 200 where multiple diagonal grooves or channels have been cut in the wall, at an angle to the horizontal of about 45 degrees to provide a "cross" pattern. The channels have a width of approximately 1.27 cm, a depth of approximately 0.0762 cm, and a separation of approximately 1.27 cm. Figure 25 is a cross-sectional view of the mold wall where multiple horizontal grooves or channels have been cut into the wall, extending near the bottom of the mold wall towards near the top of the mold wall. The channels have a width of approximately 0.4762 cm, a depth of approximately 0.2286 cm and a separation of approximately 0.4762 cm, starting from approximately 0.127 cm from the bottom of the wall. Figure 26 is a cross-sectional view of the mold wall where a single horizontal groove or channel has been cut into the wall, near the bottom of the wall. The channel preferably has a width of approximately 1.27 cm, a depth of approximately 0.508 cm, and starts approximately 0.127 cm from the bottom of the mold wall. Its cross section is shaped like a v. Figure 27 illustrates a serpentine groove or channel in the mold wall. The channel (s) shown in Figures 22-27 can be used with the mold wall 1 17 in Figure 19, in addition to being used on other side walls of the mold 84, as well as being used on walls of other unit molds of masonry, such as a mold wall for a brick mold. The preferred arrangement is to form a horizontal, hollow, individual channel near the bottom edge of the mold wall. By "gap (a)" is meant that the ratio of width G of the channel (see Figure 22A) to the maximum depth D of the channel is at least about 1: 1 and usually greater than 1: 1. (for example, at least about 2: 1). It has been found that the provision of channel 1 19 causes the texturization of the corresponding surface of the molded workpiece as it is discharged from the mold. Although not wishing to be bound by theory, it is believed that some of the filler material used to form the work piece temporarily resides in channel 1 during the molding process. This is referred to as "channel fill material". As the compressed and molded filling material is discharged from the mold cavity this channel filling material begins to be transformed or begins to break by the movement of the work piece within the mold cavity and the material of the mold. Channel fill begins to shake or roll up against the work piece's work surface, imparting a slightly rough texture to it. It seems likely that the channel filling material is constantly being changed / supplied as the work piece passes through the channel during the unloading of the work piece from the mold. Regardless of the mechanism, the surface of the passing workpiece is given a slightly rough texture through this procedure. This effect can be achieved through a single channel, or through a series of channels. At least one of the channels will be oblique (preferably perpendicular) to the cutting direction of the mold workpiece. This is important since one does not merely create a vertical strip or a series of vertical strips on the corresponding face of the block. The depth and height of each channel will be selected to provide the optimal or desired surface texturing for the intended application, taking into account the mixing design for the fill material, which includes adding size and distribution. It has been observed that if the channel is too large, some large aggregate may remain inside the channel during the block formation process, and the larger the aggregate maintained in the channel the face of the work piece will be marked in a way which is easily visible when viewed in the finished block or other masonry unit (usually an undesirable result). For most applications, it has been found that the height of the channel (dimension G of Figure 22A) will be less than about 1.90 cm, and usually less than about 1.52 cm. Channel heights of about 0.381 to about 1.52 cm are particularly useful. The depths of the channel (dimension D of Figure 22A) are usually less than about 1.27 cm and usually less than about 0.889 cm. Depths of about 0.254 to about 0.635 cm are absolutely desirable. In general, if the channel becomes wider, it can also be made very thin, so that the amount of channel filling material is not too large and the large aggregate will not remain in the channel. When the masonry unit is discharged from the mold cavity, any channel filling material remaining in the channel (s) will tend to fall out of the cana, especially during the vibration of the mold. In this regard, the preferred mold designs are self-cleaning, and it is not necessary to interrupt production to clean the mold wall of the compacted filling material. When making the channels shallow, the filling material is not retained in the channels from cycle to cycle, so that it can harden. This is undesirable and will defeat the desired objective of having a soft, uncured, fresh filling material by twisting or winding against the passage surface of a concrete masonry unit that is being discharged from the mold cavity. As shown in Figure 23, the wall has a height H and a width W for a total projected surface area equal to HxW. In a similar way, the channel has a height G for a total projected surface area equal to GxW. The ratio of HxW divided by GxW is a useful measure to know how much channeling has been made towards the surface of the mold wall. In practice, this ratio of total projected area of the mold wall to the total projected area of the channel (s) will usually be more than about 2: 1 and preferably more than about 4: 1. The ratio is approximately 10-50: 1 usually optimal. This means that the desired surface texturing can only be obtained with a modest amount of channeling. This means the construction of the mold. For many applications, it is preferred to use an individual horizontal channel located within approximately 1.27 cm, and usually less than approximately 0.254 cm., of the bottom edge or bottom of the wall, and extending substantially and completely through the wall. Typically, at least one of the channels will be separated from the top of the wall by more than 40% of the distance H from the top to the bottom of the wall, and more usually, at least one of the channels will be at or below the midpoint of the wall (50% of H). Placing in at least one of the channels below the wall (for example at least 60% of the depth and preferably at least 75% of H), will provide a more desirable surface texturing for most applications . In this regard, the location of the channel determines where the texturing on the workpiece begins, since the face of the molded workpiece that is below the lowest channel is not affected by the action of the channel and will retain its finish. of natural surface. When it is desired to obtain a surface texturing of almost the entire corresponding surface of the workpiece, at least one channel must be placed very close to the bottom of the wall since it is practical. Typically, this will be within approximately 0.254 cm from the bottom of the wall. In contrast, moving to the lowermost channel above the wall will present a portion of the face of the textured molded workpiece and a portion will not be textured.This cosmetic appearance (partially textured and partially lined) may be desired. In addition, a channel can vary in height and / or depth over its length, which can lead to different surface texturing effects on the corresponding surface of the workpiece, which can be a desired cosmetic appearance for Some applications: The use of a channel or slot in a mold wall can be to produce a light, modest or fine textured surface on the blocks, as well as on bricks, pavers and other molded masonry units. protruding lips, wall projections or grilles (as found in the patents of US Pat. No. 3,940,229; 5,078,940; 5,217,630; 5,879,603; and 6,1,3,379), although such features can be used to supplement the action described herein. However, the rapid wear problems associated with thin lips may be minimized, as they may damage the lips that result from misalignment of the head. In addition, the channel (s) can be provided on other configuration surfaces of a mold, including surfaces that are non-planar.

Additional details of molds and slots or channels in the mold walls to achieve texturing can be found in the co-pending US patent applications No. 09/691, 931 and 09/691, 898, each of which was filed on October 19, 200 and are hereby incorporated by reference in their entirety. Preferably, at least the rounded sections 1 14, 16 and the front portion of the side surfaces 106, 108 are slightly textured. This is important since the irregularities produced by the projections 16, 26 can expose portions of the block sides when the blocks are lying on an upward wall. The texturing of these lateral surfaces has the effect of disguising the fabricated appearance of the exposed portions of the blocks. If no texturing is used, then the generally smooth, slightly bright sides of the blocks tend to look very fabricated. It is preferred that the texturing be produced along about 7.62 to about 20.32 cm on each side of the block, extending over each rounded portion and a portion of each side surface, as measured from the front surface of a block with a length of 30.48. cm. However, it is contemplated and is within the scope of the invention to texturize more of the side surfaces than only the same front portions, including all side surfaces, and to texture the rear surface 1 12. The material used to form the masonry block 100 preferably it is a mixed material to further increase the appearance of rock type, with appearance of wear for time, natural. As is known in the art, the filler materials that are used to make blocks, bricks, pavers, and the like, contain aggregates such as sand and gravel, cement and water. The filling materials may contain pumice, quartzite, taconite, and other natural or man-made fillers. It may also contain other additives such as color pigment and chemicals to improve properties such as water resistance, cure resistance, and the like. The ratios of various ingredients and the types of materials and sieve profiles can be selected from experience to technique and are usually selected based on the focal availability of starting materials, technical requirements of the final products, and the type of the machine that is used. Preferably, the filler material that is used to form the block 100 is formulated to produce a mixture of colors, whereby the resulting front face 110 of the cut block 100 has a mottled appearance so that the front of the block simulates a stone or natural rock. For example, as shown in Figure 14, the front face 110 has a mottled appearance produced by a plurality of colors 122, 124. One or more additional colors may be added in order to alter the mottled appearance. However, in cases where a mottled appearance is not desired, a mixture of color fill material or a mixture of natural aggregate may be used. When looking for a mottled appearance, the filler material that is used to form the work piece and thus the resulting block (s) is preferably introduced into the mold using a divided gravity hopper and a feed box, which are known in the art, above the mold. Figure 21 shows a top view of a hopper 170 and a partition plate 172 that is mounted on the hopper 170 to help produce a stirring of colors in the filling material. The partition plate 172 extends across the width of the hopper 170, the edges of the plate 172 being removably disposed within the channels 174, 176 formed on the hopper to allow removal of the plate 172. The plate 172 also it extends vertically within the hopper 170. The plate 172 is composed of an arrangement of baffles 178 which are intended to randomly distribute each color of filling material as it is emptied into the hopper 170. Each color of filling material is emptied separately in the hopper, plate 172 randomly distributing each color on any material previously emptied into the hopper. The suction action of the feed box on the hopper as the filling material is discharged to the feed box further contributes to a random distribution of the various colors in the filling material. In addition, a stirring grid, which is known in the art, is present in the feed box to level the filling material. The action of the stirring grid also helps to stir the colors in the filling material. The filling material with randomly distributed or scrambled colors is then transferred from the feed box to the mold to produce the work piece. The stirring of the colors in the filling material produces the mottled appearance on the front surface of the block 100 once the work piece has been cut. The stirring produced by the plate 172, the suction action of the feeding box and the stirring grid is random, so that the stirring of the colors in each work piece and the resulting mottled appearance in each block is generally different for each piece. of work and block formed. In addition, the mottled appearance of the front surface will vary depending on where the workpiece is cut due to the random stirring of the colors in the workpiece. An example of a composition, based on weight, of a filler material that can be used to produce a mottled appearance using a mixture of three colors, is as follows: Gray (1/2 lot) Coal (1/2 lot) Coffee (1/2 lot) Sand 2500 2500 2500 Posts 1000 1000 1000 Cement 275 275 275 Ash trailed 100 100 1 00 Additives: RX-901 538.6 RX-901 538.6 g RX-901 38 Color: No color added black 1.79 g red 2.31 kg Black 3302.31 kg RX-901, manufactured by Grace Products, is a primary effluorescency control agent that is used to eliminate the bleed of calcium hydroxide or "liberal lime" across the face of the block. Other compositions of the filler material can also be used depending on the desired mottled appearance of the front face of! block, the composition listed above being merely illustrative. For example, a two-color filler can be used. Once the filling material has been prepared, it is transported to the block forming machine, and introduced into the mold in the commonly understood form. The block forming machine forms uncured, "raw" work pieces, which are then transported to a healing area, where the work pieces harden and gain some of their final strength. After an adequate period of curing, the workpieces are removed from the ovens, and introduced to the cutting station, adapted as described above, wherein the work pieces are cut into individual blocks. From the cutting station, the blocks are transported to a cubing station, where they are assembled into shipping cubes on wooden pallets. The buckets on the pallets are then transported to an inventory field to wait for their shipment to stores or a job site. The block 100 also includes a locating lip or tab 126 integrally formed on the lower surface 104 adjacent to, and preferably forming a portion of the rear surface 1 12. The lip 126 establishes a uniform seat for a wall formed of the blocks 100 and provides some resistance to shear stress. In the preferred configuration, the lip 126 is continuous from one side of the block 100 to the other side. However, the lip 126 need not be continuous from one side to the other, nor the lip 126 need to be contiguous with the rear wall 112. A different form of projection that functions equivalent to the lip 126 for locating the blocks can be used. The block shape shown in Figures 14-16 is preferred. However, it is contemplated and is within the scope of the invention to utilize the concepts described herein, including the irregular edges produced by the projections 16, 26, and / or the texturing of the side surfaces and / or the mottled appearance of the front surface , in other block forms. In addition, the block 100 can be formed with internal recesses to reduce the weight of the block 100. For example, Figure 17 illustrates a block 150 that is provided with an irregular front face 152 with irregular edges 152a, 152b, texturing a portion of the side surfaces 154, 156 (only a side surface 154 and the texturing thereon are seen in Figure 16), and a mottled coloration of the front face 152. Like block 100, all side surfaces 154, 156, as well as a back surface 158, can be textured. The block 150 is preferably cut from a suitable workpiece, using the cutting assemblies 12 'and 22' of Figures 1 1 and 8, respectively. The general form of block 150 is similar to that described in Figures 1-3 of the U.S. patent. A. 5,827,015. Other forms of block can be provided with one or more of these characteristics. In the preferred embodiment, the block 100 is one of a pair of blocks resulting from the cutting of a workpiece, such as the workpiece 68 in Figure 12, using cutting blade assemblies of the type illustrated in Figures 8. and 1 1. Blocks of different sizes can be formed by reducing or enlarging the size of the workpiece from which the blocks are produced. Nevertheless, as discussed above with respect to Figure 10, the workpiece 58 can be formed and then cut to produce 3 different block sizes, each of which is similar to the block 100. Furthermore, it is contemplated and is within the It is within the scope of the invention that only one of the blocks 100 can be formed from a workpiece that, after cutting, results in a piece of waste in addition to the block 100. Figure 18 illustrates a wall constructed of 3 blocks of different size, each block having a configuration similar to block 100. There are cases where it is satisfactory for a block to be provided with only an irregular edge on the front face. Therefore, it is contemplated and is within the scope of the invention that a workpiece can be cut using only one of the cutting assemblies described herein. In addition, a cutting assembly may have projections that are arranged only on one side of the cutting line.

The above specification, examples and ciatos provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims that follow.

Claims

CLAIMS 1 . - A masonry block resulting from a cutting operation in a workpiece molded through at least one cutting assembly in a block cutter having a cutting line, at least one cutting assembly including a plurality of projections disposed on at least one side of the cutting line and positioned to engage the work piece during the cutting operation, the masonry block comprising: a block body including an upper surface, a lower surface, a front surface extending from the upper and lower surfaces, a rear surface extending from the upper and lower surfaces, and lateral surfaces between the front and rear surfaces; a locating protrusion formed integrally with the block and disposed on the upper or lower surface thereof; the intersection of the front surface and the top surface defines an upper edge, and the intersection of the front surface and the bottom surface defines a lower edge; and the front surface and at least a portion of one of the upper edge and the lower edge are irregular as a result of the plurality of projections that engage the work piece during the cutting operation. 2. - The masonry block according to claim 1, wherein the block cutter includes a second cutting assembly with a plurality of projections disposed on the same side of the cutting line as the projections of the first cutting assembly, and wherein at least a portion of the upper edge and at least a portion of the lower edge of the block are irregularities as a result of the plurality of projections that engage the work piece during the cutting operation. 3. The masonry block according to claim 1, wherein at least one upper edge or one irregular lower edge is rounded. 4. The masonry block according to claim 1, wherein a portion of at least one of the side surfaces is textured as a result of providing at least one channel in a sidewall of the workpiece forming mold. 5. The masonry block according to claim 4, wherein a portion of each of the side surfaces is textured as a result of providing channels in the side walls of the workpiece forming mold. 6. The masonry block according to claim 4, wherein the textured portion of at least one side surface is adjacent to the front surface. 7. The masonry block according to claim 4, wherein the textured portion of at least one lateral surface is the entire lateral surface. 8. - The masonry block according to claim 1, further including a rounded section connecting the front surface to at least one of the side surfaces. 9. The masonry block according to claim 1, further including rounded sections connecting the front surface to both side surfaces. 1 0. - The masonry block according to claim 9, wherein each of the rounded sections is textured as a result of providing channels in the walls forming the workpiece forming mold. eleven . - The masonry block according to claim 1, wherein the front surface is mottled. 12. - The masonry block according to claim 1, wherein the mottled appearance occurs through a plurality of colors in the material forming the masonry block. 13. - The masonry block according to claim 1, wherein the locating projection comprises a locating lip. 14. - The masonry block according to claim 1, wherein the front surface is round when viewed from the side. 15. - The masonry block according to claim 1, where the projections have a cylindrical shape. 16. The masonry block according to claim 15, wherein the projections have rounded tips. 17. The masonry block according to claim 15, wherein the projections have irregular tips. 1 8. - The masonry block according to claim 15, wherein the projections have a diameter of 10 between about 1.27 to about 3.175 cm. 19. - The masonry block according to claim 1, wherein the projections comprise plates. 20. - The masonry block according to claim 1, wherein the projections are in the form of 15 pyramid twenty-one . - The masonry block according to claim 1, wherein the cutting assembly includes a cutting blade aligned with the cutting line, and wherein said projections have a tip that is positioned approximately 20 0.9525 cm above or below the top of the blade. 22. A wall formed from a plurality of masonry blocks according to claim 1. 23. - The wall according to claim 22, wherein a plurality of different sizes of the blocks are used. 25 masonry. 24. - A masonry block formed from a molded workpiece, comprising: a block body including an upper surface, a lower surface, a front face extending from the upper and lower surface, a rear surface extending between the upper surfaces and lower, and lateral surfaces between the front and rear surfaces; and wherein a portion of at least one of the surfaces is textured as a result of providing at least one channel in a wall of the workpiece forming mold. 25. - The masonry block according to claim 24, wherein the front surface is irregular as a result of the cutting of the workpiece and at least a portion of each side surface is textured as a result of providing at least one channel in each side wall of the workpiece forming mold. 26. - The masonry block according to claim 25, wherein the textured side surface portions are adjacent to the front surface. 27. The masonry block according to claim 25, wherein the texturized side surface portions are entire side surfaces. 28. The masonry block according to claim 24, wherein the back surface is textured as a result of providing a channel in a back wall of the workpiece forming mold. 29. - A block of masonry that is produced from a molded work piece that is cut into a block cutter having a cut line, the block cutter comprising a first cut assembly including a plurality of projections disposed on at least one side of the cutting line, the projections being positioned so as to couple the work piece during the cutting operation, whereby the masonry block includes at least one irregular cut edge and a surface produced by the first cutting assembly. 30. - The masonry block according to claim 29, wherein the block cutter comprises a second cutting assembly opposite the first cutting assembly, and wherein the second cutting assembly includes a plurality of projections positioned so that They couple the work piece during the cutting operation so the masonry block includes an opposite pair of irregular edges. 31 - The masonry block according to claim 29, wherein a masonry block surface includes a textured portion as a result of providing a channel in a wall of the workpiece forming mold. 32. - The masonry block according to claim 31, wherein the textured portion is on a side surface of the masonry block adjacent to its front surface. 33. - The masonry block according to claim 29, which further includes a locating protrusion integrally formed on a lower surface of the block. 34. - The masonry block according to claim 33, wherein the locating protrusion comprises a lip. 35. - The masonry block according to claim 29, wherein the irregular cut surface is med. 36. The masonry block according to claim 35, wherein the med appearance is produced through a plurality of colors in the material forming the masonry block. 37.- A method for producing a masonry block having at least one irregular cut edge and a surface, comprising: providing a masonry block cutter having a cut line with which a work piece is to be cut of masonry and is aligned, the block cutter including a first cutting assembly including a plurality of projections disposed on at least one side of the cutting line, said projections being positioned so as to couple the work piece during operation cutting; locate a masonry work piece in the masonry block cutter, so that the work piece is aligned with the cut line; and cutting the workpiece at least two pieces using the first cutting assembly. 38. - The method according to claim 37, further including the step of providing the masonry block cutter with a second cutting assembly opposite the first cutting assembly and operating in conjunction therewith, the second cutting assembly including a plurality of projections disposed on the same side of the cutting line as the projections of the first cutting assembly, said projections being positioned so as to couple the work piece during the cutting operation, whereby the masonry block includes an opposite pair of irregular cut edges. 39. - The method according to claim 38, wherein the first and second cutting assemblies are provided with a plurality of projections disposed on each side of the cutting line. 40. - A masonry block having at least one irregular cut edge and surface, the cut edge and irregular surface being produced when a molded workpiece is cut into a block cutter comprising a first cutter assembly cutting having a first cutting blade connected to a first blade support, the first blade support including a blade support surface extending from the first cutting blade on at least one side thereof, the blade support surface being arranged at an acute angle relative to the horizontal, and the blade support surface can be coupled with the workpiece during the cutting operation, and the irregular cut edge and surface being at least partially the result of the contact of the blade support surface with the workpiece. 41 - The masonry block according to claim 40, wherein the block cutter includes a second cutter blade assembly opposite the first cutter blade assembly, and wherein the second cutter blade assembly includes a second cutter blade. connected to a second blade support, the second blade support including a blade support surface extending from the second cutting blade over at least a portion thereof, the blade support surface of the second blade support being arranged at an acute angle relative to the horizontal, and the blade support surface of the second blade support can be engaged with the workpiece during the cutting operation, and the masonry block includes an opposite pair of irregular cut edges. which at least partially result from the contact of the blade support surfaces of the first and second supports of blade with the work piece. 42. - The masonry block according to claim 41, wherein the sharp angles of the blade support surfaces of the first and second blade supports are preferably between about 0 degrees and about 30 degrees. 43. - A cutting blade assembly for use in a block cutter, comprising: a cutting blade; and a plurality of projections positioned adjacent to the cutting blade on at least one side thereof, said projections and said cutting blade are fixed relative to each other during a cutting operation, whereby the projections and the blade are move simultaneously during the cutting operation. 44. - The cutting blade assembly according to claim 43, which includes a plurality of projections placed on each side of the cutting blade. 45.- The cutting blade assembly according to claim 44, wherein the cutting blade is connected to a blade holder that includes a surface extending from the cutting blade on each side thereof, the surfaces each being arranged at an acute angle relative to the horizontal, and the projections they are mounted on said surfaces. 46. The cutting blade assembly according to claim 43, wherein said projections are adjustable relative to the cutting blade. 47. The cutter blade assembly according to claim 43, wherein the projections have a cylindrical shape. 48. - The cutting blade assembly according to claim 47, wherein the projections have round tips. 49. - The cutting blade assembly according to claim 47, wherein the projections have irregular tips. 50. The cutter blade assembly according to claim 47, wherein the projections have a diameter of about 1.27 to about 3.175 cm. 51 The cutter blade assembly according to claim 43, wherein the projections comprise plates. 52. The cutter blade assembly according to claim 43, wherein the projections are pyramid-shaped. 53. - The cutting blade assembly according to claim 43, wherein the projections have a tip that is positioned approximately 0.9525 cm above or below the top of the cutting blade. 54. - A method for producing at least one masonry unit with a texture on at least one surface, the mold characterized by: a) a plurality of side walls that define a mold cavity open at its top and bottom to allow the introduction of masonry filling material into the mold cavity through its open top and to discharge the molded filler material in the form of a molded masonry unit through its open bottom; b) at least one surface texturizing channel is formed on the face of at least one of the side walls, the channel extending through the face of the side wall in a direction not parallel to the cutting direction of the mold , the channel has a height of at least about 1,905 cm and a depth of less than about 1.27 cm, and at least a portion of the channel is separated from the top of the wall where it forms through a distance that is greater than about 40% of the distance from the top of the side wall to the bottom of the side wall; and c) presents a ratio of the total projected area of the side wall provided with the channel to the total projected area of all the channels greater than approximately 2: 1. 55.- A masonry block cutter having a cut line with which it is aligning a workpiece for cutting the workpiece into at least two pieces, comprising a first cutting assembly including a plurality of projections disposed on at least one side of the cutting line, said projections being positioned so that travel to the work piece as it is cut into at least two pieces by the block cutter, whereby the first cut assembly contributes to the formation of at least one irregular cut edge and surface on at least one of the cutting pieces. SUMMARY A masonry block that is produced from a workpiece that is cut into a block cutting assembly, which uses any of a variety of projections to supplement or replace the action of the cutting blade to cut and cover the workpiece of work. The resulting masonry block has features that give the masonry block a wear appearance over time.