US20090000234A1 - Concrete blocks with non-geometric face surfaces - Google Patents
Concrete blocks with non-geometric face surfaces Download PDFInfo
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- US20090000234A1 US20090000234A1 US11/768,664 US76866407A US2009000234A1 US 20090000234 A1 US20090000234 A1 US 20090000234A1 US 76866407 A US76866407 A US 76866407A US 2009000234 A1 US2009000234 A1 US 2009000234A1
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- block
- blocks
- mold box
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- concrete
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- 238000000034 method Methods 0.000 claims description 7
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- 238000004519 manufacturing process Methods 0.000 claims description 4
- 238000009434 installation Methods 0.000 claims description 3
- 230000006641 stabilisation Effects 0.000 claims description 2
- 238000011105 stabilization Methods 0.000 claims description 2
- 239000003086 colorant Substances 0.000 abstract description 9
- 230000015572 biosynthetic process Effects 0.000 abstract 1
- 238000010276 construction Methods 0.000 description 4
- 239000004575 stone Substances 0.000 description 4
- 230000004888 barrier function Effects 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 238000009435 building construction Methods 0.000 description 1
- 230000000593 degrading effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000008240 homogeneous mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000004570 mortar (masonry) Substances 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D29/00—Independent underground or underwater structures; Retaining walls
- E02D29/02—Retaining or protecting walls
- E02D29/025—Retaining or protecting walls made up of similar modular elements stacked without mortar
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
- B28B15/005—Machines using pallets co-operating with a bottomless mould; Feeding or discharging means for pallets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
- B28B7/007—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces with moulding surfaces simulating natural effets, e.g. wood or stone
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/24—Unitary mould structures with a plurality of moulding spaces, e.g. moulds divided into multiple moulding spaces by integratable partitions, mould part structures providing a number of moulding spaces in mutual co-operation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/28—Cores; Mandrels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/16—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
- B28B7/18—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article
- B28B7/183—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article for building blocks or similar block-shaped objects
Definitions
- Concrete blocks have been used to create a wide variety of mortared and mortarless walls. These walls have been used in applications ranging from retaining walls for sloped areas, building construction, sound barriers, and other landscaping and structural applications. While blocks have primarily been valued for their ability to meet structural requirements, the demand for more attractive block products and walls is increasing.
- a concrete block has a face surface that is convergent toward a generally horizontal edge with respect to a plane extending vertically through the block, the face surface having a non-geometric pattern molded thereon, the face surface being configured such that no first point on said face surface is spaced further from said plane than any other point on said face surface positioned in a vertical line further from the generally horizontal edge than said first point.
- Another embodiment in accordance with the invention includes a mold box for forming concrete blocks in a high speed block machine.
- the mold box has an open top and bottom, opposed longitudinal side panels and opposed lateral end panels.
- There is a reciprocating shoe for reciprocatory up and down motion to engage a raw concrete mix within the mold box so as to configure a surface of the blocks as they are oriented within the mold box.
- a non-geometric pattern is embossed on at least one surface of the mold box, the surface being tapered so as to allow the block formed within the mold to disengage from the mold box.
- a method for the manufacture of concrete blocks having non-geometric patterns on their face surfaces includes providing a mold box having an open top and bottom, opposed longitudinal side panels and opposed lateral side panels.
- the mold box has a reciprocating top shoe for reciprocatory up and down motion to engage a raw concrete mix within the mold box so as to configure a surface of the blocks as they are oriented within the mold box and a divider plate for separating individual blocks within the mold box.
- the divider plate has opposed, outward facing surfaces that are downwardly convergent with respect to a vertical plane passing through the divider plate.
- Each convergent surface has a non-geometric pattern embossed thereon and each convergent surface is configured such that no first point on said surface is spaced further from said plane than any other point on said surface positioned directly vertically above said first point.
- the method further involves charging concrete into the open top of the mold box, and forcing the concrete into intimate contact with the convergent surfaces of the divider plate to form a molded block unit comprising two or more blocks.
- the mold box and divider plate are then vertically separated from the molded block unit with the block unit being spaced beneath the mold box and divider plate.
- a wall constructed of concrete blocks having various sizes and various patterns formed on their face surfaces includes a plurality of individual blocks stacked in an array of superimposed rows, with each block having at least one molded face surface with a non-geometric pattern formed thereon.
- the wall includes a first block having a first face surface with a length that is a multiple of an integer greater than one of the length of a second face of a second block.
- the wall also has a third block having a third face surface with a height that is a multiple of an integer greater than one of the height of a fourth face of a fourth block.
- the wall has blocks of various sizes and various face surface patterns distributed throughout the wall to create a non-uniform appearance.
- FIG. 1 is a perspective view of a block in accordance with embodiments of the invention.
- FIG. 2 is a cross section views of the block shown in FIG. 1 taken from the perspective indicated at “A.”
- FIG. 3 is a cross section views of the block shown in FIG. 1 taken from the perspective indicated at “B.”
- FIG. 4 is a cross section views of the block shown in FIG. 1 taken from the perspective indicated at “C.”
- FIG. 5 is a perspective view of a block in accordance with embodiments of the invention and a corresponding mold surface.
- FIG. 6 is a perspective view of a division plate in accordance with embodiments of the invention.
- FIG. 7 is a perspective view of the other side of the division plate of FIG. 6 .
- FIG. 8 is a perspective view of a mold box in accordance with embodiments of the invention and a set of blocks that could be formed therein.
- FIG. 9 is a cross section of the mold box of FIG. 8 as a set of blocks is being formed.
- FIG. 10 is a perspective view of a mold box in accordance with embodiments of the invention and blocks formed from the mold box.
- FIG. 11 shows an example of a concrete blocks in accordance with embodiments of the invention.
- FIG. 12 shows an example of a concrete blocks in accordance with embodiments of the invention.
- FIG. 13 shows an example of a concrete blocks in accordance with embodiments of the invention.
- FIG. 14 shows an example of a concrete blocks in accordance with embodiments of the invention.
- FIG. 15 shows an example of a concrete blocks in accordance with embodiments of the invention.
- FIG. 16 shows an example of a concrete blocks in accordance with embodiments of the invention.
- FIG. 17 is an elevation view of a collection of blocks in accordance with embodiments of the invention.
- FIG. 18 is an elevation view of a wall in accordance with embodiments of the invention.
- FIG. 19 is an elevation view of a wall in accordance with embodiments of the invention.
- Concrete blocks in accordance with the invention may be used in many applications including but not limited to retaining walls, sound barriers, landscaping walls, etc.
- the blocks and molds described herein allow for the construction of unique and attractive wall structures usable in a variety of applications.
- the ability to combine blocks of various sizes, colors, and surface patterns to create walls with desirable aesthetic features is but one advantage associated with this disclosure.
- FIG. 1 is a perspective view of a block in accordance with embodiments of the invention.
- FIGS. 2 , 3 , and 4 are cross section views of the block shown in FIG. 1 , the cross sections views taken from the perspectives indicated at “A,” “B,” and “C,” respectively.
- the block 50 is generally rectangular in shape and has bottom 60 , top 70 , rear 80 , two sides 90 and front 100 .
- the bottom 60 and rear 80 surfaces of this embodiment are generally planar and arranged generally normal to one another.
- the sides 90 may be in normal arrangement to the front surface 100 when viewed from above or one or both may be angularly arranged thereto to allow for the construction of curved retaining walls.
- the side walls 90 are angled but the rear wall 80 extends beyond the intersection with the side walls 90 so that the rear wall is essentially the same length as the front face 100 .
- the portions of the rear wall 80 that extends beyond the intersection of the rear wall 80 with the side walls 90 could be removed to allow for the construction of curved portions of retaining wall.
- the top 70 includes a first support area 1 10 defined over a predetermined area of the top for the support of additional blocks and a vertically extending shoulder 120 adjacent the front surface of the block.
- the embodiment includes a second top surface 130 at the uppermost end of the extending shoulder.
- the support area 110 and the vertical shoulder 120 provide a locating surface to receive an additional vertically positioned block on top of the block 50 .
- the additional block may be positioned rearwardly from the front surface 100 of the receiving and supporting block whereby a wall of tiers of such blocks may extend rearwardly and upwardly from a support surface 110 .
- Block 50 includes a front surface 100 that includes a rearwardly and upwardly directed face surface 10 and a lower generally vertical portion 140 generally normal to the bottom surface 60 .
- the lower vertical portion 140 may be configured to interact with the vertical shoulder 120 of an additional block onto which the block is placed.
- there is no separate lower generally vertical portion and the face surface 10 of the block extends all of the way to the bottom surface 60 of the block 50 .
- the face surface 100 could be rearwardly and downwardly directed so that the upper portion of the face surface 100 extended beyond the lower portion.
- the front surface 100 of block 50 includes a face surface 10 that has a non-geometric pattern 20 molded thereon.
- the block 50 has a face surface 10 that is convergent toward a generally horizontal edge 15 with respect to a plane V extending vertically through the block.
- the face surface 10 is configured such that no first point 30 on the face surface is spaced further from said plane than any other point 40 on said face surface 100 positioned in a vertical line further from the generally horizontal edge 15 than said first point 30 .
- the face surface 100 converges upwardly, so no first point 30 on the face surface is spaced further from said plane than any other point 40 on said face surface positioned directly below said first point 30 .
- Each vertical segment of the face surface 100 of the embodiment in FIG. 1 is upwardly convergent so that the block may be formed in a high speed block machine and disengage from the mold box without significantly degrading the non-geometric pattern 20 on the face surface.
- Blocks could also be formed “upside down” in a high speed block machine so that the block as installed would have a face surface that is downwardly convergent with respect to a vertical plane.
- an intricate non-geometric pattern can be formed while keeping each vertical segment upwardly convergent as shown in FIGS. 2-4 .
- a non-geometric pattern may be contrasted with a geometric pattern, which uses simple geometric forms like circles and squares.
- Such non-geometric patterns may include, but are not limited to, patterns resembling worn or hewn natural stone, patterns resembling layered or sedimentary stone, patterns resembling rugged stone, and others that are all contemplated within the scope of this disclosure.
- Blocks such as those shown in FIG. 1 may be made of concrete that is a variegated mixture of concrete that is dyed or otherwise different in color.
- a non-homogeneous mixture of concrete of different colors may be injected into a mold to form blocks of essentially random colors and combinations of colors.
- the veining or dappling effect of the various colors of the concrete creates more interesting looking blocks.
- the walls formed from these collections of blocks, particularly if the collection contains blocks of various sizes, colors and color combinations, and face surface patterns, are more attractive and appealing in many applications than walls constructed of more uniform blocks.
- FIG. 5 is a perspective view of a block in accordance with embodiments of the invention and a corresponding mold surface.
- the block 50 has a face surface 10 with a non-geometric pattern 20 molded thereon.
- the corresponding mold surface 155 is embossed with a non-geometric pattern 20 that is transferred to the block 50 during the block production process.
- the mold surface 155 of the embodiment shown in FIG. 5 is a division plate 150 configured for installation in a mold box.
- the division plate is tapered at an angle T so that it is narrower at the bottom than the top.
- the mold surface 155 is configured such that each point on the mold surface is spaced farther from a vertical plane than any other point directly below the first point.
- FIG. 6 is a perspective view of a division plate in accordance with embodiments of the invention.
- FIG. 7 is a perspective view of the other side of the division plate of FIG. 6 .
- the division plate 150 has a non-geometric pattern 20 embossed thereon.
- the non-geometric pattern 20 on each side of the division plate is different, allowing for the production of two blocks with different non-geometric patterns at the same time.
- the division plate 150 is thicker at the top than at the bottom as described above, and the face surfaces of the division plate 150 are configured such that each point on the mold surface is spaced farther from a vertical plane than any other point directly below it. It may be advantageous to consider issues like plate thickness while designing the different non-geometric patterns on each side of the plate to ensure that the plate does not become too thin at a point where each face patter recedes.
- FIG. 8 is a perspective view of a mold box in accordance with embodiments of the invention and a set of blocks that could be formed therein.
- the mold box of FIG. 8 may be used for forming concrete blocks in a high speed block machine.
- the mold box 175 has an open top and bottom.
- the box 175 has opposed longitudinal side panels 160 and opposed lateral end panels 170 .
- a reciprocating shoe 180 may engage a raw concrete mix within the mold box 175 so as to configure the top surface of the blocks as they are oriented within the mold box.
- This “top surface” may in fact be the a bottom or other surface as the blocks are ultimately oriented, and the reference to top only applies to the block as oriented within the mold box.
- the mold box also includes a moveable planar base support 210 that acts as the bottom of the mold box to form blocks 50 .
- the longitudinal side panels 160 of the embodiment of FIG. 8 have optional core bar receiving openings 165 formed therein and an optional core bar 200 that may be reciprocally introduced and removed from the mold box 175 to configure a bottom surface of the blocks 50 as they are oriented in the mold box.
- blocks 50 may have a lower generally vertical portion 140 formed on the front surface.
- the core bar 200 is positioned within the mold box 175 .
- the core bare 200 is then removed from the mold box 175 through the core bar opening 165 .
- the blocks are then allowed to exit the mold box 175 through the bottom of the mold box.
- core bars 200 of various sizes may be used to create blocks 50 having different set backs for the generally vertical portion 140 .
- the various set backs for the generally vertical portion 140 provide varied set-backs for individual blocks when the generally vertical portion 140 interacts with the vertical shoulder 120 of a lower block to provide a more interesting appearance to the wall.
- the core bar receiving openings 165 may be large enough to accommodate core bars 200 of various sizes so that blocks 50 having set backs for the generally vertical portion 140 of various depths may be formed using the same mold box 175 , or different mold boxes 175 may be used with corresponding core bars 200 .
- a non-geometric pattern 20 is embossed on at least one surface of the mold box, the surface being tapered so as to allow the block formed within the mold box 175 to disengage from the bottom of the mold box.
- the surface of the mold box that is embossed with a non-geometric pattern 20 is a divider plate 150 .
- Each side of the divider plate 150 may have a different non-geometric pattern embossed thereon so that the blocks 50 formed in the mold box will each have a different non-geometric pattern molded on it.
- the longitudinal side panels 160 and/or the lateral end panels 170 may be embossed with a tapered non-geometric pattern 20 in addition to or instead of the divider plate 150 .
- edges 190 of the shoe 180 adjacent to the surface of the mold box that is embossed with a non-geometric pattern is shaped to coincide with the upper edge of the surface of the mold box that is embossed, in this case the divider plate 150 .
- the shoe may be configured with an irregular surface to better form the top surface (as oriented in the mold box) of the block 50 and then assist in the removal of the formed blocks from the mold.
- FIG. 9 is a cross section of the mold box of FIG. 8 as a set of blocks is being formed.
- Each block 50 is formed between the shoe 180 , the planar base support 210 , the divider plate 150 , the longitudinal side panels 160 (not shown), and opposed lateral end panels 170 .
- the optional core bar 200 forms a generally vertical portion 140 on the front face of the block. Once the blocks are formed, the core bar 200 is removed and the moveable planar base support 210 is lowered relative to the other elements of the mold box so that the blocks 50 slide out of the mold box.
- the divider plate 150 is embossed with a non-geometric pattern, and each point on the divider plate 150 is closer to the center of the divider plate 150 than any point above that point so that the blocks 50 may slide out of the bottom of the mold box without being marred by the embossed surface.
- FIG. 10 is a perspective view of a mold box in accordance with embodiments of the invention and blocks formed from the mold box.
- a mold box 175 for forming concrete blocks 50 in a high speed block machine has an open top and bottom, opposed lateral side panels 160 and opposed longitudinal side panels 170 .
- the assembly also includes a reciprocating top shoe 180 for reciprocatory up and down motion to engage a raw concrete mix so as to configure the top surface of the blocks 50 as they are oriented within the mold box.
- the assembly may also include a moveable planar base support 210 that acts as the bottom of the mold box as it is filled with concrete mix.
- the mold box may also include one or more divider plates 150 for separating blocks units within the mold box.
- the divider plate 150 may have a non-geometric pattern 20 embossed on it that will impress or emboss a non-geometric pattern 20 on the face surface 10 of the block 50 .
- each side of the divider plate 150 has a different non-geometric pattern 20 embossed on it, providing the blocks 50 with a wider variety of face surface 10 appearances.
- the divider plate 150 is generally thicker at the top than at the bottom. This allows the formed block 50 to be removed from the bottom of the mold without the divider plate 150 marring the face surface 10 of the block. Even though the divider plate 150 is generally thicker at the top, a non-geometric pattern 20 may be embossed on the divider plate that has various contours and ridges. This can be accomplished by ensuring that each vertical segment of the divider plate 150 is always getting thicker as you move from the bottom to the top of the divider plate 150 .
- each segment would generally get thicker as you move to the top of the divider plate, although different segments would get thicker at different points between the top and bottom of the divider plate 150 .
- Each first point on the divider plate 150 is closer to the vertical center of the divider plate 150 than any point directly above that first point.
- the non-geometric pattern 20 formed on the face surface 10 may resemble a naturally occurring stone.
- inside surfaces of the longitudinal side panels 160 and lateral side panels 170 are also embossed with a non-geometric pattern 20 .
- These side panels are also generally tapered to allow the block formed therein to be removed through the bottom of the mold and to disengage readily from the side panel without disturbing the pattern 10 embossed on the block 50 .
- This embodiment also includes two divider plates 150 , each with two sides that are embossed with a non-geometric pattern 20 . All of these embossed surfaces may be embossed with different non-geometric patterns to provide a wide variety of face surfaces 10 to the blocks 50 , all of which enhance the aesthetic appeal of walls constructed from such blocks.
- FIGS. 11-16 show examples of other concrete blocks in accordance with embodiments of the invention. These blocks all have face surfaces with non-geometric patterns 20 formed thereon. Each of the generally vertical face surfaces 10 are tapered so that they converge toward a generally horizontal edge 15 with respect to a plane extending vertically through the block, the plane oriented parallel to the horizontal edge 15 edge of the face surface and behind the face surface. Each point on the generally vertical face surface 10 is spaced further from said plane than any other point on said face surface positioned in a vertical line further from the generally horizontal edge 15 than said first point. It should be noted that the horizontal edge on the blocks in FIGS. 14 and 16 is the bottom edge of the block and the face surfaces 10 of these blocks converge downwardly toward a vertical plane located behind the face surface 10 while the blocks of FIGS. 11-13 and 15 converge upwardly in that sense.
- the block of FIG. 11 is a freestanding landscape block.
- This embodiment has parallel load bearing surfaces 220 , first and second ends 230 , and first and second opposed face surfaces 10 .
- the ends of this block are transverse to the load bearing surfaces 220 and the opposed face surfaces 10 .
- the load bearing surfaces of the block have mating interlocks 240 comprising arcuate cores and protruding arcuate interlocks receivable in the cores.
- the interlocking cores are not vertically aligned with the protruding interlocks on the same building block.
- the block may be configured so that each end of a block comprises a half interlock and adjacent ends of a pair of blocks in a row together define an interlock portion that interlocks with a mating full interlock portion carried by a block in a vertically adjacent row of blocks.
- Blocks of this type are described more fully in U.S. Pat. No. 6,948,282, entitled “Interlocking Building Block,” the relevant portions of which are hereby incorporate by reference.
- the block of FIG. 12 is a freestanding landscape block usable as an end block in conjunction with the block of FIG. 11 .
- This block has parallel load bearing surfaces 220 , an end 230 , and first and second opposed face surfaces 10 , and a third face surface 10 opposite end 230 .
- the end of this block are comprises a half interlock 240 that interacts with an adjacent end of a block in a row to define an interlock portion that interlocks with a mating full interlock portion carried by a block in a vertically adjacent row of blocks.
- Blocks of this type are described more fully in U.S. Pat. No. 6,948,282, the relevant portions of which are hereby incorporate by reference.
- the block of FIG. 13 is a cap block for use with blocks such as the block of FIG. 1 .
- This block has a top face portion 35 with a non-geometric pattern 25 molded thereon.
- the top face 15 is formed by a reciprocating shoe so there are no limitations as to how the non-geometric pattern 25 is configured because the shoe lowers to mold the top face and raises away vertically to disengage the block.
- the front face 10 has a non-geometric pattern 20 molded thereon. This non-geometric pattern may be formed by a vertical mold surface and is configured such that each point of the face surface is closer to the rear wall 80 than any point directly below that point on the face surface 10 .
- the block has a front wall 100 that includes the face surface 10 and a lower generally vertical portion 140 .
- the lower vertical portion 140 may be configured to interact with the vertical shoulder 120 of an additional block 50 ( FIG. 1 ) onto which the block is placed.
- the block of FIG. 14 is a block for use in creating structural walls without mortar.
- the block has opposed face surface 10 with a non-geometric pattern molded thereon.
- the generally horizontal surface 280 resembles a truncated cone when viewed from the end 300 .
- the generally horizontal surface 260 is configured to interact with the surface 280 of an adjacent block by being angle inwardly so that the angled surface 250 will engage the angled surface 280 to form a stable wall of blocks.
- End 300 is recessed relative to the face surfaces 10 and end 310 extends beyond the face surfaces 10 so that adjacent blocks in a row of blocks interact end-to-end to increase wall stability. Blocks of this type are described more fully in U.S. Pat. No. 6,082,067 entitled “Dry Stackable Block Structures,” the relevant portions of which are hereby incorporated by reference.
- the block of FIG. 15 is a retaining wall block that uses a pin and grove design to assist in stabilizing the wall.
- the block of FIG. 15 has a face surface 10 with a non-geometric pattern 20 as described above.
- the side walls 320 taper rearwardly such that the rear wall 330 is shorter than the face surface 10 .
- the passages 340 pass completely through the block and allow for the installation of pins through the blocks to aid in the stabilization of a wall constructed from the blocks. Blocks of this type are described more fully in U.S. Patent Application Pub. No. US 2006/0117697, entitled “Modular Block System,” the relevant portions of which are hereby incorporated by reference.
- the block of FIG. 16 is a traditional concrete building block used on construction of concrete walls. This block is usable in mortared applications.
- the basic block is well known in the art, but the embodiment of FIG. 16 has a non-geometric pattern 20 molded thereon that may be formed by a vertical mold surface and is configured such that each point of the face surface is closer to the longitudinal center line of the block than is any point directly above that point on the face surface 10 .
- This embodiment of this block is formed upside down in a high speed block making machine.
- a block formed right side up would have a face surface 10 configured such that each point of the face surface is closer to the longitudinal center line of the block than is any point directly below that point on the face surface 10 .
- FIG. 17 is an elevation view of a collection of blocks in accordance with embodiments of the invention.
- the face surface 10 of each block is shown.
- the face surface 10 is a surface that will be visible when the block is installed in a wall. Other surfaces of the block may also be visible, but it is the face surface that is the predominant feature of the block once it is installed in a wall. Some blocks will have only one face surface, as in the main load bearing blocks of a retaining wall. Other blocks will have two or more face surfaces.
- a wall with two visible sides will be primarily constructed from blocks that have two face surfaces on opposite sides of the block.
- a block used at the end or top of a wall may have even more face surfaces, as will a block used to make a corner in the wall.
- FIG. 17 four sizes of blocks are generally indicated at “W,”, “X,” “Y.” and “Z.”
- the length of the face surfaces 10 of the blocks in each group is indicated by LA where A is the letter associated with the group.
- L W is the length of the face surface 10 of the blocks in group W.
- the height of the face surfaces 10 of the block in each group is indicated by H A , where A is the letter associated with the group.
- the height of the face surfaces of blocks of group Y is H Y .
- L W is an integer multiple greater than 1 of L Y and L Z .
- the integer is 2, meaning that the face surface 10 of the blocks W is twice as long as the face surface 10 of blocks Y and Z.
- L Y in this embodiment equals L A and is therefore also two times L X and L Z . In other embodiments the integer could be 3 or greater.
- H W equals H X and the face surfaces of the W and X blocks are twice the height of the face surfaces 10 of the Y and Z blocks.
- the lengths and heights of the blocks in the collection are equal to each other or integer multiples greater than one of each other allows walls to be constructed with blocks of various sizes arranged in a variety of patterns because, for example, two blocks that are twice as long as a single other block of the collection, or three that are three times as long, may be used in lieu of a single block, and need not necessarily be adjacent to each other. If properly arranged, eventually the combination of blocks that are integer multiples of each other in height and length of face surface can form a uniform wall with a unique appearance.
- Blocks such as those shown in the collection of FIG. 17 may also have a non-geometric pattern 20 molded thereon.
- this pattern 20 is formed by embossed elements of a mold box usable in a high speed block making machine.
- a collection of blocks may include several different patterns 20 on each block. Thus the variety of patterns and block sizes may combine to create an even more visually interesting wall design.
- FIG. 18 is an elevation view of a wall in accordance with embodiments of the invention.
- the wall of FIG. 18 combines the elements of various non-geometric patterns, block sizes, and block colors to create a visually pleasing non-manufactured looking concrete wall. In the case of retaining walls as discussed earlier, the wall could also use various setback depths, to provide even more interest.
- the wall of FIG. 18 could be constructed of blocks such as those described herein or any blocks known in the art that are amenable to the techniques taught and claimed in this application.
- FIG. 18 demonstrates how a collection of blocks in accordance with the invention can be arranged to form a wall having interesting appeal with only four sizes of face surfaces 10 and a limited number of non-geometric patterns. Because the height and length of the face surfaces 10 of the blocks are either equal to the dimensions of adjacent blocks or multiples of integers greater than one of the length and/or the width of adjacent blocks, the collection of blocks can be used to create a pseudorandom looking wall while easily consuming a collection of blocks such as that in FIG. 17 .
- the resultant wall can be built to a variety of heights and can be used in a wide variety of applications.
- FIG. 19 is an elevation view of a wall in accordance with embodiments of the invention.
- the wall of FIG. 19 only includes one size of blocks, but still shows the interesting and appealing looks that can be achieved using a collection of blocks with non-geometric face patterns in accordance with the invention.
- Other arrangements of blocks of various sizes are contemplated by the inventors and will occur to those or ordinary skill upon reading this disclosure.
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Abstract
Concrete blocks having face surfaces embossed with non-geometric patterns. The blocks may be of various sizes with some having faces surfaces with lengths and heights that are multiples other blocks. The blocks may have multiple sizes, colors or combinations of colors, face surface patterns, and set back configurations. Also, walls formed from such blocks and mold boxes usable in the formation of the blocks are included.
Description
- Concrete blocks have been used to create a wide variety of mortared and mortarless walls. These walls have been used in applications ranging from retaining walls for sloped areas, building construction, sound barriers, and other landscaping and structural applications. While blocks have primarily been valued for their ability to meet structural requirements, the demand for more attractive block products and walls is increasing.
- In one embodiment in accordance with the invention, a concrete block has a face surface that is convergent toward a generally horizontal edge with respect to a plane extending vertically through the block, the face surface having a non-geometric pattern molded thereon, the face surface being configured such that no first point on said face surface is spaced further from said plane than any other point on said face surface positioned in a vertical line further from the generally horizontal edge than said first point.
- Another embodiment in accordance with the invention includes a mold box for forming concrete blocks in a high speed block machine. The mold box has an open top and bottom, opposed longitudinal side panels and opposed lateral end panels. There is a reciprocating shoe for reciprocatory up and down motion to engage a raw concrete mix within the mold box so as to configure a surface of the blocks as they are oriented within the mold box. A non-geometric pattern is embossed on at least one surface of the mold box, the surface being tapered so as to allow the block formed within the mold to disengage from the mold box.
- In another embodiment in accordance with the invention, a method for the manufacture of concrete blocks having non-geometric patterns on their face surfaces is disclosed. The method includes providing a mold box having an open top and bottom, opposed longitudinal side panels and opposed lateral side panels. The mold box has a reciprocating top shoe for reciprocatory up and down motion to engage a raw concrete mix within the mold box so as to configure a surface of the blocks as they are oriented within the mold box and a divider plate for separating individual blocks within the mold box. The divider plate has opposed, outward facing surfaces that are downwardly convergent with respect to a vertical plane passing through the divider plate. Each convergent surface has a non-geometric pattern embossed thereon and each convergent surface is configured such that no first point on said surface is spaced further from said plane than any other point on said surface positioned directly vertically above said first point. The method further involves charging concrete into the open top of the mold box, and forcing the concrete into intimate contact with the convergent surfaces of the divider plate to form a molded block unit comprising two or more blocks. The mold box and divider plate are then vertically separated from the molded block unit with the block unit being spaced beneath the mold box and divider plate.
- In another embodiment in accordance with the invention, a wall constructed of concrete blocks having various sizes and various patterns formed on their face surfaces includes a plurality of individual blocks stacked in an array of superimposed rows, with each block having at least one molded face surface with a non-geometric pattern formed thereon. The wall includes a first block having a first face surface with a length that is a multiple of an integer greater than one of the length of a second face of a second block. The wall also has a third block having a third face surface with a height that is a multiple of an integer greater than one of the height of a fourth face of a fourth block. The wall has blocks of various sizes and various face surface patterns distributed throughout the wall to create a non-uniform appearance.
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FIG. 1 is a perspective view of a block in accordance with embodiments of the invention. -
FIG. 2 is a cross section views of the block shown inFIG. 1 taken from the perspective indicated at “A.” -
FIG. 3 is a cross section views of the block shown inFIG. 1 taken from the perspective indicated at “B.” -
FIG. 4 is a cross section views of the block shown inFIG. 1 taken from the perspective indicated at “C.” -
FIG. 5 is a perspective view of a block in accordance with embodiments of the invention and a corresponding mold surface. -
FIG. 6 is a perspective view of a division plate in accordance with embodiments of the invention. -
FIG. 7 is a perspective view of the other side of the division plate ofFIG. 6 . -
FIG. 8 is a perspective view of a mold box in accordance with embodiments of the invention and a set of blocks that could be formed therein. -
FIG. 9 is a cross section of the mold box ofFIG. 8 as a set of blocks is being formed. -
FIG. 10 is a perspective view of a mold box in accordance with embodiments of the invention and blocks formed from the mold box. -
FIG. 11 shows an example of a concrete blocks in accordance with embodiments of the invention. -
FIG. 12 shows an example of a concrete blocks in accordance with embodiments of the invention. -
FIG. 13 shows an example of a concrete blocks in accordance with embodiments of the invention. -
FIG. 14 shows an example of a concrete blocks in accordance with embodiments of the invention. -
FIG. 15 shows an example of a concrete blocks in accordance with embodiments of the invention. -
FIG. 16 shows an example of a concrete blocks in accordance with embodiments of the invention. -
FIG. 17 is an elevation view of a collection of blocks in accordance with embodiments of the invention. -
FIG. 18 is an elevation view of a wall in accordance with embodiments of the invention. -
FIG. 19 is an elevation view of a wall in accordance with embodiments of the invention. - Concrete blocks in accordance with the invention may be used in many applications including but not limited to retaining walls, sound barriers, landscaping walls, etc. The blocks and molds described herein allow for the construction of unique and attractive wall structures usable in a variety of applications. The ability to combine blocks of various sizes, colors, and surface patterns to create walls with desirable aesthetic features is but one advantage associated with this disclosure.
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FIG. 1 is a perspective view of a block in accordance with embodiments of the invention.FIGS. 2 , 3, and 4 are cross section views of the block shown inFIG. 1 , the cross sections views taken from the perspectives indicated at “A,” “B,” and “C,” respectively. Theblock 50 is generally rectangular in shape and hasbottom 60,top 70, rear 80, twosides 90 andfront 100. Thebottom 60 and rear 80 surfaces of this embodiment are generally planar and arranged generally normal to one another. Thesides 90 may be in normal arrangement to thefront surface 100 when viewed from above or one or both may be angularly arranged thereto to allow for the construction of curved retaining walls. In the embodiment shown, theside walls 90 are angled but therear wall 80 extends beyond the intersection with theside walls 90 so that the rear wall is essentially the same length as thefront face 100. The portions of therear wall 80 that extends beyond the intersection of therear wall 80 with theside walls 90 could be removed to allow for the construction of curved portions of retaining wall. - The
top 70 includes a first support area 1 10 defined over a predetermined area of the top for the support of additional blocks and a vertically extendingshoulder 120 adjacent the front surface of the block. The embodiment includes a secondtop surface 130 at the uppermost end of the extending shoulder. When used to construct walls, thesupport area 110 and thevertical shoulder 120 provide a locating surface to receive an additional vertically positioned block on top of theblock 50. The additional block may be positioned rearwardly from thefront surface 100 of the receiving and supporting block whereby a wall of tiers of such blocks may extend rearwardly and upwardly from asupport surface 110. -
Block 50 includes afront surface 100 that includes a rearwardly and upwardly directedface surface 10 and a lower generallyvertical portion 140 generally normal to thebottom surface 60. The lowervertical portion 140 may be configured to interact with thevertical shoulder 120 of an additional block onto which the block is placed. In an alternative embodiment, there is no separate lower generally vertical portion and theface surface 10 of the block extends all of the way to thebottom surface 60 of theblock 50. In another alternative embodiment, theface surface 100 could be rearwardly and downwardly directed so that the upper portion of theface surface 100 extended beyond the lower portion. - The
front surface 100 ofblock 50 includes aface surface 10 that has anon-geometric pattern 20 molded thereon. As can best be seen inFIGS. 2-4 , theblock 50 has aface surface 10 that is convergent toward a generallyhorizontal edge 15 with respect to a plane V extending vertically through the block. Theface surface 10 is configured such that nofirst point 30 on the face surface is spaced further from said plane than anyother point 40 on saidface surface 100 positioned in a vertical line further from the generallyhorizontal edge 15 than saidfirst point 30. In this particular embodiment theface surface 100 converges upwardly, so nofirst point 30 on the face surface is spaced further from said plane than anyother point 40 on said face surface positioned directly below saidfirst point 30. Each vertical segment of theface surface 100 of the embodiment inFIG. 1 is upwardly convergent so that the block may be formed in a high speed block machine and disengage from the mold box without significantly degrading thenon-geometric pattern 20 on the face surface. Blocks could also be formed “upside down” in a high speed block machine so that the block as installed would have a face surface that is downwardly convergent with respect to a vertical plane. As can be seen from the exemplary face surface inFIG. 1 , an intricate non-geometric pattern can be formed while keeping each vertical segment upwardly convergent as shown inFIGS. 2-4 . - A non-geometric pattern may be contrasted with a geometric pattern, which uses simple geometric forms like circles and squares. Such non-geometric patterns may include, but are not limited to, patterns resembling worn or hewn natural stone, patterns resembling layered or sedimentary stone, patterns resembling rugged stone, and others that are all contemplated within the scope of this disclosure.
- Blocks such as those shown in
FIG. 1 may be made of concrete that is a variegated mixture of concrete that is dyed or otherwise different in color. In other words, a non-homogeneous mixture of concrete of different colors may be injected into a mold to form blocks of essentially random colors and combinations of colors. The veining or dappling effect of the various colors of the concrete creates more interesting looking blocks. The walls formed from these collections of blocks, particularly if the collection contains blocks of various sizes, colors and color combinations, and face surface patterns, are more attractive and appealing in many applications than walls constructed of more uniform blocks. -
FIG. 5 is a perspective view of a block in accordance with embodiments of the invention and a corresponding mold surface. Theblock 50 has aface surface 10 with anon-geometric pattern 20 molded thereon. The correspondingmold surface 155 is embossed with anon-geometric pattern 20 that is transferred to theblock 50 during the block production process. Themold surface 155 of the embodiment shown inFIG. 5 is adivision plate 150 configured for installation in a mold box. The division plate is tapered at an angle T so that it is narrower at the bottom than the top. Themold surface 155 is configured such that each point on the mold surface is spaced farther from a vertical plane than any other point directly below the first point. As theblock 50 is disengaged from themold surface 155 by moving down relative to themold surface 155, the block disengages from the mold surface without direct interference by thesurface 155. -
FIG. 6 is a perspective view of a division plate in accordance with embodiments of the invention.FIG. 7 is a perspective view of the other side of the division plate ofFIG. 6 . Thedivision plate 150 has anon-geometric pattern 20 embossed thereon. Thenon-geometric pattern 20 on each side of the division plate is different, allowing for the production of two blocks with different non-geometric patterns at the same time. Thedivision plate 150 is thicker at the top than at the bottom as described above, and the face surfaces of thedivision plate 150 are configured such that each point on the mold surface is spaced farther from a vertical plane than any other point directly below it. It may be advantageous to consider issues like plate thickness while designing the different non-geometric patterns on each side of the plate to ensure that the plate does not become too thin at a point where each face patter recedes. -
FIG. 8 is a perspective view of a mold box in accordance with embodiments of the invention and a set of blocks that could be formed therein. The mold box ofFIG. 8 may be used for forming concrete blocks in a high speed block machine. Themold box 175 has an open top and bottom. Thebox 175 has opposedlongitudinal side panels 160 and opposedlateral end panels 170. Areciprocating shoe 180 may engage a raw concrete mix within themold box 175 so as to configure the top surface of the blocks as they are oriented within the mold box. This “top surface” may in fact be the a bottom or other surface as the blocks are ultimately oriented, and the reference to top only applies to the block as oriented within the mold box. The same applies to references to bottom and side surfaces. The mold box also includes a moveableplanar base support 210 that acts as the bottom of the mold box to form blocks 50. - The
longitudinal side panels 160 of the embodiment ofFIG. 8 have optional corebar receiving openings 165 formed therein and anoptional core bar 200 that may be reciprocally introduced and removed from themold box 175 to configure a bottom surface of theblocks 50 as they are oriented in the mold box. For example blocks 50 may have a lower generallyvertical portion 140 formed on the front surface. As themold box 175 is filled with raw concrete, thecore bar 200 is positioned within themold box 175. The core bare 200 is then removed from themold box 175 through thecore bar opening 165. The blocks are then allowed to exit themold box 175 through the bottom of the mold box. - In some embodiments in accordance with the invention, core bars 200 of various sizes may be used to create
blocks 50 having different set backs for the generallyvertical portion 140. When these blocks are used to form a wall, the various set backs for the generallyvertical portion 140 provide varied set-backs for individual blocks when the generallyvertical portion 140 interacts with thevertical shoulder 120 of a lower block to provide a more interesting appearance to the wall. The corebar receiving openings 165 may be large enough to accommodatecore bars 200 of various sizes so thatblocks 50 having set backs for the generallyvertical portion 140 of various depths may be formed using thesame mold box 175, ordifferent mold boxes 175 may be used with corresponding core bars 200. - A
non-geometric pattern 20 is embossed on at least one surface of the mold box, the surface being tapered so as to allow the block formed within themold box 175 to disengage from the bottom of the mold box. In the embodiment shown inFIG. 8 , the surface of the mold box that is embossed with anon-geometric pattern 20 is adivider plate 150. Each side of thedivider plate 150 may have a different non-geometric pattern embossed thereon so that theblocks 50 formed in the mold box will each have a different non-geometric pattern molded on it. In alternative embodiments of amold box 175 in accordance with the invention, thelongitudinal side panels 160 and/or thelateral end panels 170 may be embossed with a taperednon-geometric pattern 20 in addition to or instead of thedivider plate 150. - In this embodiment the
edges 190 of theshoe 180 adjacent to the surface of the mold box that is embossed with a non-geometric pattern is shaped to coincide with the upper edge of the surface of the mold box that is embossed, in this case thedivider plate 150. Because the top of the embossed edge may be somewhat irregular, the shoe may be configured with an irregular surface to better form the top surface (as oriented in the mold box) of theblock 50 and then assist in the removal of the formed blocks from the mold. -
FIG. 9 is a cross section of the mold box ofFIG. 8 as a set of blocks is being formed. Eachblock 50 is formed between theshoe 180, theplanar base support 210, thedivider plate 150, the longitudinal side panels 160 (not shown), and opposedlateral end panels 170. Theoptional core bar 200 forms a generallyvertical portion 140 on the front face of the block. Once the blocks are formed, thecore bar 200 is removed and the moveableplanar base support 210 is lowered relative to the other elements of the mold box so that theblocks 50 slide out of the mold box. Thedivider plate 150 is embossed with a non-geometric pattern, and each point on thedivider plate 150 is closer to the center of thedivider plate 150 than any point above that point so that theblocks 50 may slide out of the bottom of the mold box without being marred by the embossed surface. -
FIG. 10 is a perspective view of a mold box in accordance with embodiments of the invention and blocks formed from the mold box. Amold box 175 for formingconcrete blocks 50 in a high speed block machine has an open top and bottom, opposedlateral side panels 160 and opposedlongitudinal side panels 170. The assembly also includes a reciprocatingtop shoe 180 for reciprocatory up and down motion to engage a raw concrete mix so as to configure the top surface of theblocks 50 as they are oriented within the mold box. The assembly may also include a moveableplanar base support 210 that acts as the bottom of the mold box as it is filled with concrete mix. The mold box may also include one ormore divider plates 150 for separating blocks units within the mold box. Thedivider plate 150 may have anon-geometric pattern 20 embossed on it that will impress or emboss anon-geometric pattern 20 on theface surface 10 of theblock 50. In some embodiments each side of thedivider plate 150 has a differentnon-geometric pattern 20 embossed on it, providing theblocks 50 with a wider variety offace surface 10 appearances. - The
divider plate 150 is generally thicker at the top than at the bottom. This allows the formedblock 50 to be removed from the bottom of the mold without thedivider plate 150 marring theface surface 10 of the block. Even though thedivider plate 150 is generally thicker at the top, anon-geometric pattern 20 may be embossed on the divider plate that has various contours and ridges. This can be accomplished by ensuring that each vertical segment of thedivider plate 150 is always getting thicker as you move from the bottom to the top of thedivider plate 150. In other words, if one were to segment thedivider plate 150 into multiple vertically divided segments, each segment would generally get thicker as you move to the top of the divider plate, although different segments would get thicker at different points between the top and bottom of thedivider plate 150. Each first point on thedivider plate 150 is closer to the vertical center of thedivider plate 150 than any point directly above that first point. In some embodiments, thenon-geometric pattern 20 formed on theface surface 10 may resemble a naturally occurring stone. - In the embodiment shown in
FIG. 10 , inside surfaces of thelongitudinal side panels 160 andlateral side panels 170 are also embossed with anon-geometric pattern 20. These side panels are also generally tapered to allow the block formed therein to be removed through the bottom of the mold and to disengage readily from the side panel without disturbing thepattern 10 embossed on theblock 50. This embodiment also includes twodivider plates 150, each with two sides that are embossed with anon-geometric pattern 20. All of these embossed surfaces may be embossed with different non-geometric patterns to provide a wide variety of face surfaces 10 to theblocks 50, all of which enhance the aesthetic appeal of walls constructed from such blocks. -
FIGS. 11-16 show examples of other concrete blocks in accordance with embodiments of the invention. These blocks all have face surfaces withnon-geometric patterns 20 formed thereon. Each of the generally vertical face surfaces 10 are tapered so that they converge toward a generallyhorizontal edge 15 with respect to a plane extending vertically through the block, the plane oriented parallel to thehorizontal edge 15 edge of the face surface and behind the face surface. Each point on the generallyvertical face surface 10 is spaced further from said plane than any other point on said face surface positioned in a vertical line further from the generallyhorizontal edge 15 than said first point. It should be noted that the horizontal edge on the blocks inFIGS. 14 and 16 is the bottom edge of the block and the face surfaces 10 of these blocks converge downwardly toward a vertical plane located behind theface surface 10 while the blocks ofFIGS. 11-13 and 15 converge upwardly in that sense. - The block of
FIG. 11 is a freestanding landscape block. This embodiment has parallelload bearing surfaces 220, first and second ends 230, and first and second opposed face surfaces 10. The ends of this block are transverse to theload bearing surfaces 220 and the opposed face surfaces 10. The load bearing surfaces of the block havemating interlocks 240 comprising arcuate cores and protruding arcuate interlocks receivable in the cores. The interlocking cores are not vertically aligned with the protruding interlocks on the same building block. The block may be configured so that each end of a block comprises a half interlock and adjacent ends of a pair of blocks in a row together define an interlock portion that interlocks with a mating full interlock portion carried by a block in a vertically adjacent row of blocks. Blocks of this type are described more fully in U.S. Pat. No. 6,948,282, entitled “Interlocking Building Block,” the relevant portions of which are hereby incorporate by reference. - The block of
FIG. 12 is a freestanding landscape block usable as an end block in conjunction with the block ofFIG. 11 . This block has parallelload bearing surfaces 220, anend 230, and first and second opposed face surfaces 10, and athird face surface 10opposite end 230. The end of this block are comprises ahalf interlock 240 that interacts with an adjacent end of a block in a row to define an interlock portion that interlocks with a mating full interlock portion carried by a block in a vertically adjacent row of blocks. Blocks of this type are described more fully in U.S. Pat. No. 6,948,282, the relevant portions of which are hereby incorporate by reference. - The block of
FIG. 13 is a cap block for use with blocks such as the block ofFIG. 1 . This block has atop face portion 35 with anon-geometric pattern 25 molded thereon. Thetop face 15 is formed by a reciprocating shoe so there are no limitations as to how thenon-geometric pattern 25 is configured because the shoe lowers to mold the top face and raises away vertically to disengage the block. Thefront face 10 has anon-geometric pattern 20 molded thereon. This non-geometric pattern may be formed by a vertical mold surface and is configured such that each point of the face surface is closer to therear wall 80 than any point directly below that point on theface surface 10. The block has afront wall 100 that includes theface surface 10 and a lower generallyvertical portion 140. The lowervertical portion 140 may be configured to interact with thevertical shoulder 120 of an additional block 50 (FIG. 1 ) onto which the block is placed. In an alternative embodiment, there is no separate lower generally vertical portion and theface surface 10 of the block extends all of the way to the bottom surface of the block. - The block of
FIG. 14 is a block for use in creating structural walls without mortar. The block has opposedface surface 10 with a non-geometric pattern molded thereon. The generallyhorizontal surface 280 resembles a truncated cone when viewed from theend 300. The generallyhorizontal surface 260 is configured to interact with thesurface 280 of an adjacent block by being angle inwardly so that theangled surface 250 will engage theangled surface 280 to form a stable wall of blocks.End 300 is recessed relative to the face surfaces 10 and end 310 extends beyond the face surfaces 10 so that adjacent blocks in a row of blocks interact end-to-end to increase wall stability. Blocks of this type are described more fully in U.S. Pat. No. 6,082,067 entitled “Dry Stackable Block Structures,” the relevant portions of which are hereby incorporated by reference. - The block of
FIG. 15 is a retaining wall block that uses a pin and grove design to assist in stabilizing the wall. The block ofFIG. 15 has aface surface 10 with anon-geometric pattern 20 as described above. Theside walls 320 taper rearwardly such that therear wall 330 is shorter than theface surface 10. There aregrooves 350 andpassages 340 located within thegrooves 350. Thepassages 340 pass completely through the block and allow for the installation of pins through the blocks to aid in the stabilization of a wall constructed from the blocks. Blocks of this type are described more fully in U.S. Patent Application Pub. No. US 2006/0117697, entitled “Modular Block System,” the relevant portions of which are hereby incorporated by reference. - The block of
FIG. 16 is a traditional concrete building block used on construction of concrete walls. This block is usable in mortared applications. The basic block is well known in the art, but the embodiment ofFIG. 16 has anon-geometric pattern 20 molded thereon that may be formed by a vertical mold surface and is configured such that each point of the face surface is closer to the longitudinal center line of the block than is any point directly above that point on theface surface 10. This embodiment of this block is formed upside down in a high speed block making machine. A block formed right side up would have aface surface 10 configured such that each point of the face surface is closer to the longitudinal center line of the block than is any point directly below that point on theface surface 10. -
FIG. 17 is an elevation view of a collection of blocks in accordance with embodiments of the invention. Theface surface 10 of each block is shown. The face surface10 is a surface that will be visible when the block is installed in a wall. Other surfaces of the block may also be visible, but it is the face surface that is the predominant feature of the block once it is installed in a wall. Some blocks will have only one face surface, as in the main load bearing blocks of a retaining wall. Other blocks will have two or more face surfaces. A wall with two visible sides will be primarily constructed from blocks that have two face surfaces on opposite sides of the block. A block used at the end or top of a wall may have even more face surfaces, as will a block used to make a corner in the wall. - In
FIG. 17 , four sizes of blocks are generally indicated at “W,”, “X,” “Y.” and “Z.” The length of the face surfaces 10 of the blocks in each group is indicated by LA where A is the letter associated with the group. For example, LW is the length of theface surface 10 of the blocks in group W. Similarly, the height of the face surfaces 10 of the block in each group is indicated by HA, where A is the letter associated with the group. The height of the face surfaces of blocks of group Y is HY. - In the exemplary collection of blocks of
FIG. 17 LW is an integer multiple greater than 1 of LY and LZ. In this example, the integer is 2, meaning that theface surface 10 of the blocks W is twice as long as theface surface 10 of blocks Y and Z. LY in this embodiment equals LA and is therefore also two times LX and LZ. In other embodiments the integer could be 3 or greater. Also, in the collection ofFIG. 17 , HW equals HX and the face surfaces of the W and X blocks are twice the height of the face surfaces 10 of the Y and Z blocks. - The fact that the lengths and heights of the blocks in the collection are equal to each other or integer multiples greater than one of each other allows walls to be constructed with blocks of various sizes arranged in a variety of patterns because, for example, two blocks that are twice as long as a single other block of the collection, or three that are three times as long, may be used in lieu of a single block, and need not necessarily be adjacent to each other. If properly arranged, eventually the combination of blocks that are integer multiples of each other in height and length of face surface can form a uniform wall with a unique appearance.
- Blocks such as those shown in the collection of
FIG. 17 may also have anon-geometric pattern 20 molded thereon. In some embodiments in accordance with the invention, thispattern 20 is formed by embossed elements of a mold box usable in a high speed block making machine. A collection of blocks may include severaldifferent patterns 20 on each block. Thus the variety of patterns and block sizes may combine to create an even more visually interesting wall design. -
FIG. 18 is an elevation view of a wall in accordance with embodiments of the invention. The wall ofFIG. 18 combines the elements of various non-geometric patterns, block sizes, and block colors to create a visually pleasing non-manufactured looking concrete wall. In the case of retaining walls as discussed earlier, the wall could also use various setback depths, to provide even more interest. The wall ofFIG. 18 could be constructed of blocks such as those described herein or any blocks known in the art that are amenable to the techniques taught and claimed in this application. -
FIG. 18 demonstrates how a collection of blocks in accordance with the invention can be arranged to form a wall having interesting appeal with only four sizes of face surfaces 10 and a limited number of non-geometric patterns. Because the height and length of the face surfaces 10 of the blocks are either equal to the dimensions of adjacent blocks or multiples of integers greater than one of the length and/or the width of adjacent blocks, the collection of blocks can be used to create a pseudorandom looking wall while easily consuming a collection of blocks such as that inFIG. 17 . The resultant wall can be built to a variety of heights and can be used in a wide variety of applications. -
FIG. 19 is an elevation view of a wall in accordance with embodiments of the invention. The wall ofFIG. 19 only includes one size of blocks, but still shows the interesting and appealing looks that can be achieved using a collection of blocks with non-geometric face patterns in accordance with the invention. Other arrangements of blocks of various sizes are contemplated by the inventors and will occur to those or ordinary skill upon reading this disclosure. - It will be appreciated that various modifications may be made to the techniques of the present invention; it being further understood that the examples given herein are for purposes of illustration only and are not to be construed as a limitation upon the scope to which the invention is otherwise entitled.
Claims (24)
1. A concrete block comprising a face surface that is convergent toward a generally horizontal edge with respect to a plane extending vertically through the block, the face surface having a non-geometric pattern molded thereon, the face surface being configured such that no first point on said face surface is spaced further from said plane than any other point on said face surface positioned in a vertical line further from the generally horizontal edge than said first point.
2. The concrete block of claim 1 , wherein the block is a retaining wall block.
3. The concrete block of claim 2 , wherein the block has a first load bearing surface, a second load bearing surface, and, rear, side and front surfaces, said first load bearing and rear surfaces being generally planar and arranged generally normal to one another, said second load bearing surface including a support area defined over a predetermined area for the support of additional blocks, a vertically extending shoulder adjacent said front surface of said block and a surface at the end of said extending shoulder parallel to the second load bearing surface, said support area and said vertical shoulder providing a locating surface to receive an additional vertically positioned block thereon wherein the additional block may be positioned rearwardly from the front surface of the receiving and supporting block whereby a wall of tiers of such blocks may extend rearwardly and upwardly from a support surface.
4. The concrete block of claim 3 , said front surface further including a generally vertical portion generally normal to said first load bearing surface, said vertical portion configured to interact with the vertical shoulder of an additional block onto which the block is placed.
5. The concrete block of claim 2 , the block having first and second load bearing surfaces, rear, side and front surfaces, the side surfaces tapering rearwardly such that the rear surface is shorter than the front surface, the first load bearing surface having grooves defined thereon, the block having passages beginning within the grooves that pass completely through the block and allow for the installation of pins through the blocks to aid in the stabilization of a wall constructed from a plurality of the blocks.
6. The concrete block of claim 1 , wherein the block is a freestanding mortarless wall block.
7. The concrete block of claim 6 , wherein the block has opposed front and rear face surfaces opposed ends, a first generally horizontal surface resembling a truncated cone when viewed from an end, a second generally horizontal surface configured to interact with the first horizontal surface of a lower block by being angled inwardly and upwardly so that the inwardly angled second generally horizontal surface of a block surface will interact with the angled first generally horizontal surface of a vertically stacked adjacent block to form a stable wall of blocks.
8. The concrete block of claim 7 , wherein one end is recessed relative to the face surfaces and the other end extends beyond the face surfaces so that adjacent blocks in a row of blocks interact end-to-end to increase wall stability.
9. The concrete block of claim 6 , the block having first and second parallel load bearing surfaces, first and second ends, and first and second opposed face surfaces, the ends being transverse to the load bearing surfaces and the opposed face surfaces, the load bearing surfaces of the block having mating interlocks comprising arcuate cores and protruding arcuate interlocks receivable in the cores, wherein the interlocking cores are not vertically aligned with the protruding interlocks on the same building block, the block being configured so that each end of a block comprises a half interlock and adjacent ends of a pair of blocks in a row together define an interlock portion that interlocks with a mating full interlock portion carried by a block in an adjacent row of blocks.
10. The block of claim 9 , wherein each of the first and second opposed face surfaces has a different non-geometric pattern molded thereon.
11. A mold box for forming concrete blocks in a high speed block machine, the mold box having an open top and bottom, opposed longitudinal side panels and opposed lateral end panels;
a reciprocating shoe for reciprocatory up and down motion to engage a raw concrete mix within the mold box so as to configure a surface of the blocks as they are oriented within the mold box; and
a non-geometric pattern embossed on at least one surface of the mold box, the surface being tapered so as to allow the block formed within the mold to disengage from the mold box.
12. The mold box of claim 11 , further comprising a divider plate for separating blocks units within the mold box, the divider plate having opposed, outward facing surfaces that are downwardly convergent with respect to a vertical plane passing through the divider plate, each convergent surface having a non-geometric pattern embossed thereon and each convergent surface being configured such that no first point on said surface is spaced further from said plane than any other point on said surface positioned directly vertically above said first point.
13. The mold box of claim 12 , wherein one convergent surface of the divider plate has a non-geometric pattern embossed thereon that is different from the non-geometric pattern embossed on the other convergent surface.
14. The mold box of claim 11 , further comprising a movable planar base support arranged to travel along a generally horizontal axis of motion and to support said mold box.
15. The mold box of claim 11 , wherein the lateral side panels have core bar receiving openings formed therein and a core bar that may be reciprocally introduced and removed from the mold box to configure a bottom surface of the blocks as they are oriented in the mold box.
16. The mold box of claim 15 , further comprising core bars of various sizes, wherein the core bar receiving openings are large enough to accommodate core bars of various sizes so that blocks having grooves of various sizes may be formed using the same mold box.
17. The mold box of claim 14 , wherein the support is a conveyor belt.
18. The mold box of claim 12 , wherein the inside surfaces of the lateral side panels and/or the longitudinal walls are embossed with a non-geometric pattern.
19. The mold box of claim 12 , further comprising a second divider plate, wherein each side of each divider plate has a different non-geometric pattern embossed thereon.
20. The mold box of claim 18 , wherein each non-geometric pattern embossed on the divider plate is different from each non-geometric pattern embossed on the longitudinal side panels and/or the lateral walls, and each non-geometric pattern embossed on the longitudinal side panels and/or the lateral side panels is different from each other.
21. A method for the manufacture of concrete blocks having non-geometric patterns on their face surfaces comprising:
providing a mold box having an open top and bottom, opposed longitudinal side panels and opposed lateral side panels; a reciprocating top shoe for reciprocatory up and down motion to engage a raw concrete mix within the mold box so as to configure a surface of the blocks as they are oriented within the mold box; and a divider plate for separating individual blocks within the mold box, the divider plate having opposed, outward facing surfaces that are downwardly convergent with respect to a vertical plane passing through the divider plate, each convergent surface having a non-geometric pattern embossed thereon and each convergent surface being configured such that no first point on said surface is spaced further from said plane than any other point on said surface positioned directly vertically above said first point
charging concrete into the open top of the mold box, and forcing the concrete into intimate contact with the convergent surfaces of the divider plate to form a molded block unit comprising two or more blocks,
vertically separating the mold box and divider plate from the molded block unit with the block unit being spaced beneath the mold box and divider plate.
22. The method of claim 21 , wherein one or more of the longitudinal side panels and/or the lateral side panels has a non-geometric pattern embossed thereon.
23. A wall constructed of concrete blocks having various sizes and various patterns formed on their face surfaces comprising:
a plurality of individual blocks stacked in an array of superimposed rows, with each block having at least one molded face surface with a non-geometric pattern formed thereon;
at least a first block of the plurality of blocks having a first face surface with a length that is a multiple of an integer greater than one of the length of a second face of a second block; and
at least a third block having a third face surface with a height that is a multiple of an integer greater than one of the height of a fourth face of a fourth block, wherein blocks of various sizes and various face surface patterns are distributed throughout the wall to create a non-uniform appearance.
24. The wall of claim 23 , wherein the wall is a mortarless retaining wall and each block has a vertically extending shoulder adjacent said face surface of said block and extending entirely therealong to provide a continuous block positioning member in close association to said face surface wherein an additional block is positioned rearwardly from the face surface of a receiving and supporting block whereby a wall of tiers of such blocks extend rearwardly and upwardly from a support surface.
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/768,664 US20090000234A1 (en) | 2007-06-26 | 2007-06-26 | Concrete blocks with non-geometric face surfaces |
MX2009013895A MX2009013895A (en) | 2007-06-26 | 2008-05-13 | Concrete blocks with non-geometric face surfaces. |
CA002664839A CA2664839A1 (en) | 2007-06-26 | 2008-05-13 | Concrete blocks with non-geometric face surfaces |
AU2008269002A AU2008269002A1 (en) | 2007-06-26 | 2008-05-13 | Concrete blocks with non-geometric face surfaces |
EP08755370A EP2171162A1 (en) | 2007-06-26 | 2008-05-13 | Concrete blocks with non-geometric face surfaces |
PCT/US2008/063502 WO2009002623A1 (en) | 2007-06-26 | 2008-05-13 | Concrete blocks with non-geometric face surfaces |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/768,664 US20090000234A1 (en) | 2007-06-26 | 2007-06-26 | Concrete blocks with non-geometric face surfaces |
Publications (1)
Publication Number | Publication Date |
---|---|
US20090000234A1 true US20090000234A1 (en) | 2009-01-01 |
Family
ID=39638899
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/768,664 Abandoned US20090000234A1 (en) | 2007-06-26 | 2007-06-26 | Concrete blocks with non-geometric face surfaces |
Country Status (6)
Country | Link |
---|---|
US (1) | US20090000234A1 (en) |
EP (1) | EP2171162A1 (en) |
AU (1) | AU2008269002A1 (en) |
CA (1) | CA2664839A1 (en) |
MX (1) | MX2009013895A (en) |
WO (1) | WO2009002623A1 (en) |
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US20090301028A1 (en) * | 2008-03-07 | 2009-12-10 | Steven Pfoff | Method for constructing cultured stone block buildings |
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WO2011163118A1 (en) * | 2010-06-23 | 2011-12-29 | Rosetta Hardscapes, Llc | Method and apparatus for dry casting concrete blocks having a decorative face |
US20130031861A1 (en) * | 2010-04-29 | 2013-02-07 | Lg Hausys, Ltd. | Block deck using concrete |
WO2014089663A1 (en) * | 2012-12-14 | 2014-06-19 | Kondratiuk Oleksii Mikhailovich | Method of manufacturing building blocks and a mold for manufacturing row building blocks or corner building blocks |
US9145676B2 (en) * | 2011-11-09 | 2015-09-29 | E.P. Henry Corporation | Masonry block with taper |
US9168673B2 (en) | 2014-03-05 | 2015-10-27 | Michael Coggin | Device for removing debris from passages in manufactured modular blocks |
US9945118B2 (en) * | 2015-05-05 | 2018-04-17 | Risi Stone, Inc. | Method and mold for manufacturing an interlocking concrete retaining wall block |
USD893053S1 (en) | 2018-08-14 | 2020-08-11 | Allan Block, Llc | Retaining wall block |
USD893760S1 (en) | 2018-08-14 | 2020-08-18 | Allan Block, Llc | Retaining wall block |
USD950775S1 (en) * | 2020-10-09 | 2022-05-03 | Shoreloc Design Group, Inc. | Masonry block |
USD952907S1 (en) * | 2020-10-09 | 2022-05-24 | Shoreline Stone Manufacturing Carib, Inc. | Masonry block |
US20220259812A1 (en) * | 2020-10-09 | 2022-08-18 | Shoreloc Design Group, Inc. | Masonry Block |
US11598094B2 (en) * | 2017-10-25 | 2023-03-07 | Keystone Retaining Wall Systems Llc | Retaining wall block and retaining wall block system |
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Cited By (17)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110005157A1 (en) * | 2006-11-22 | 2011-01-13 | Pratt Daniel J | Masonry Block and Associated Methods |
US20090301028A1 (en) * | 2008-03-07 | 2009-12-10 | Steven Pfoff | Method for constructing cultured stone block buildings |
US20130031861A1 (en) * | 2010-04-29 | 2013-02-07 | Lg Hausys, Ltd. | Block deck using concrete |
US8820023B2 (en) * | 2010-04-29 | 2014-09-02 | Lg Hausys, Ltd. | Block deck using concrete |
WO2011163118A1 (en) * | 2010-06-23 | 2011-12-29 | Rosetta Hardscapes, Llc | Method and apparatus for dry casting concrete blocks having a decorative face |
US9145676B2 (en) * | 2011-11-09 | 2015-09-29 | E.P. Henry Corporation | Masonry block with taper |
EA032593B1 (en) * | 2012-12-14 | 2019-06-28 | Общество с ограниченной ответственностью "Технопарк" | Method of manufacturing building blocks (embodiments) and mold for manufacturing row building blocks or corner building blocks (embodiments) |
WO2014089663A1 (en) * | 2012-12-14 | 2014-06-19 | Kondratiuk Oleksii Mikhailovich | Method of manufacturing building blocks and a mold for manufacturing row building blocks or corner building blocks |
US9168673B2 (en) | 2014-03-05 | 2015-10-27 | Michael Coggin | Device for removing debris from passages in manufactured modular blocks |
US9945118B2 (en) * | 2015-05-05 | 2018-04-17 | Risi Stone, Inc. | Method and mold for manufacturing an interlocking concrete retaining wall block |
US10760267B2 (en) | 2015-05-05 | 2020-09-01 | Risi Stone Inc. | Method and mold for manufacturing an interlocking concrete retaining wall block |
US11598094B2 (en) * | 2017-10-25 | 2023-03-07 | Keystone Retaining Wall Systems Llc | Retaining wall block and retaining wall block system |
USD893053S1 (en) | 2018-08-14 | 2020-08-11 | Allan Block, Llc | Retaining wall block |
USD893760S1 (en) | 2018-08-14 | 2020-08-18 | Allan Block, Llc | Retaining wall block |
USD950775S1 (en) * | 2020-10-09 | 2022-05-03 | Shoreloc Design Group, Inc. | Masonry block |
USD952907S1 (en) * | 2020-10-09 | 2022-05-24 | Shoreline Stone Manufacturing Carib, Inc. | Masonry block |
US20220259812A1 (en) * | 2020-10-09 | 2022-08-18 | Shoreloc Design Group, Inc. | Masonry Block |
Also Published As
Publication number | Publication date |
---|---|
AU2008269002A1 (en) | 2008-12-31 |
MX2009013895A (en) | 2010-04-01 |
CA2664839A1 (en) | 2008-12-31 |
EP2171162A1 (en) | 2010-04-07 |
WO2009002623A1 (en) | 2008-12-31 |
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Legal Events
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Owner name: ALLAN BLOCK CORPORATION, MINNESOTA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:BOTT, TIMOTHY A.;GRAVIER, ROBERT A.;REEL/FRAME:019832/0154 Effective date: 20070831 |
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Owner name: ALLAN BLOCK, LLC, MINNESOTA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:ALLAN BLOCK CORPORATION;REEL/FRAME:025600/0783 Effective date: 20101214 |
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STCB | Information on status: application discontinuation |
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