US2508901A - Method for forming building blocks - Google Patents

Description

May 23, 1950 R. G. BELLEZZA METHOD FOR FORMING BUILDINQBLOCKS S@ 2. /3 if $5 ,6

a 2 f kx 1 l l l l l l l /w// l Patented May 23, 1950 METHOD FOR FORMING BUILDING BLOCKS Russell G. Bellezza, Baltimore, Md., assigner to Locke, Incorporated, Baltimore, Md., a corporation of Maryland Application October 9, 1944, Serial No. 557,852

4 Claims. 1

The invention relates to a method of forming building blocks, and more particularly to a method of forming the same of ceramic material.

Toward the accomplishment of this end, the principal object oi the invention is to provide a method by which a building block of hollow boxlike formation may be readily, easily and economically manufactured.

Another object of the invention is to provide a method of forming a building block having suiiicient structural rigidity, strength or characteristics to permit the employment or use thereof in building structures, and possessing at the same time an exceedingly high thermal value so that the block serves not only as a construction unit, but as an insulating medium as well.

Other objects of the invention will appear in connection with the more detailed description of the invention appearing hereinafter when considered together with the accompanying drawings in which:

Figure 1 is a vertical side sectional view of a building block and mold therefor which embodies the present invention;

Figure 2 is a vertical transverse sectional view taken along the lines 2 2 of Figure l looking in the direction of the arrows;

Figure 3 is a horizontal sectional view taken along the lines 3-3 of Figure l looking in the direction of the arrows;

Figure 4 is a side elevational view shown partly in section of a completed building block removed from the mold;

Figure 5 is an end elevational view having a portion thereof shown in section to illustrate more completely the invention of a completed building block removed from the mold;

Figure 6 is a side elevational view of a modified form of the building .block shown in Figures l through 5 inclusive, and being shown partially in section;

Figure 7 is an end elevational view of the modiiied form of a building block shown in Figure 6 and being illustrated partially in section.

Referring now to the drawings in detail, and more particularly to Figures l to 5 thereof, the numeral I indicates a portion of a mold in cross section, comprising transversely spaced side plates 2 and 2a extending preferably for the full area or height oi the mold, and having interposed therebetween angularly disposed intermediate sections or plates 3 and ta which have their contiguous extremities mitered as at 4 to present a completely enclosed box-like structure dening a material-receiving area or cavity 5 therebetween. Positioned at the central portion of each intermediate section 3 and 3a and desrably outstanding therefrom at the corners thereof is a lug 6 which extends intoV a correspondinglyv a proper assembly thereof as well as retain them in a predetermined relation or assembly. Any' clamping means (not shown) may be employed to act transversely or horizontally of the mold,

urging the side plates toward one another.

The mold I is formed of plaster of Paris which has an interior conguration to agree with or conform to the desired conformation of the eX- terior of the object to be formed or, as in the instant case, a building block generally indicated by the reference character 8. An aperture or access opening 9 is provided in one of the intermediate mold sections in desirably the upper- 'most portion thereof through which fluid ceramic material may be introduced. The fluid ceramic material is poured into the mold until it completely fills the same and, by reason of the abvsorbent characteristics of the plaster of Paris,

the iluid, carrier or water mixed into or forming a part ofthe fluid ceramic material Ais absorbed by the mold structure. This absorption by the mold structure. therefore, causesthe ceramic material adjacent the inner dening walls of the -mold structure to become hardened 'or solidified.

It will be noted that the opening 9 is of considerable dimension so that it may form a reservoir or well to hold suicient iluid ceramic material to be drawn from during the absorption period and thereby insure a complete filling of the interior of the mold structure.

After a predetermined period, hardening of the ceramic material will continue and progress inl wardly of the mold structure so as to form a block structure such as illustrated at 8. When the walls of the building block have reached a thickness such as that illustrated in the drawings, the mold is inverted from the position shown in Figures l and 2 so as to permit the fluid ceramic material to be discharged or escape from the interior of the thus formed block and mold through the opening 9. This procedure, therefore, leaves the ceramic building block with side and intermediate or connecting walls Il) and Il respectively, with a continuation of the opening The lugs and dowels form an in-' terlock between the respective plates for insuring 9 extending through one of the connecting walls, as indicated by the diagrammatic lines l2 in Figures 1 and 2. While the mold is in this inserted draining position, a plug i3, which may also be of plaster of Paris, is inserted into the opening 9 after the major portion or substantially all of the fluid ceramic material has been discharged irom, the: mold.'l Aften the; insertion ofi the plug I3; acontinuedfdraining-of the interiorof the mold will result in the aperture l2 being lled with fluid ceramic material to also becomebeing lifted; oi of; the:v remaining intermediate section*- or ip latei` Atrthis; stage ofthe procedure;A the hardened-' ceramici materia-l formedv by, the aperture I 2 which extends:v above the, plane of the associated connecting` wall, may -be Asevered-by` meansgoia wireorfanyfotherfcutting means. The.; buildingblock is; then: allowedto` dry.` to what is commonly known or-termed; as a bonedry state, atzwhich'time an orifice; Meis formed inv theblock and-1 comprises an, outer. portion thereof conically shaped; andan innenportion thereofcylindrically. formed; of; a veryfminute` or small diam,- eteror.; bore; Glazing: material is thenapplied; to,V outer or -frontandrear surfaces or; facesl5; of theblocleaswell asV to the defining surface ofitl'lej-conicallS/` shapedrpprtion of' the oriiice The block is'then in` condition forv itsfinal,L step ofY formation whichfis thearingoperation. Itwill; beV noted that the side' walls. l0 areYV of slightly greater4 extent than: the parallelogram as s defined by thev intermediate orV connectingy walls ll` so thatithere isformed on each side oi-the blocka. continuous or uninterruptedvilange l5: which extends beyond? the planer of the .intermediate wall andthereby.- forms acavity |11 for theireception of any typeof bonding or: binding. material employed during theA assemblage of a plurality offv blockslin a wall'structure.k

Extending in opposite directions: from. transverselyspaced' intermediatefor connecting walls@ are staggered'studs or.I spuds I3 formedl integralA with the block; These spuds form ring feetV` upon which, during they ringoperation ol"4 the ceramicV block, the latterlv is adapted"v to. rest. Whenglazel materialis: applied to thefaces |51 itfwill'be noted that'ifY the glazing materialV should.. come int'o Contact with a support orsagger: (not. shown) during the ringf operation, the` glaze would form a bond between the blockV and the sagger resulting in the completed glazed block beingbroken ordamaged Y in removing the block fromY the sagger. Byproviding;y the iiring` feet fere with one another during an assemblage of blocks in the formation of a wall structure.

Prior to the ring operation of the block, there is, as previously related, a particularly shaped oriiice I4 formed in one of the connecting walls and having the defining surface of the conically shaped portion thereof covered with a glazing material1 sothatduring the ringoperation of theblock, the air entrapped within the block will be free to escape through the orifice and, as the iiring operation continues or progresses, more and moreair will be driven or forced out of the hollow interior cf'the block until nally, at approximately theV temperature of vitrification of .the glazing.; material, a very small or minute amountofair willYT be present in the block. At this stage of the firing operation, the glazing material'willcreepor progress toward the cylindricaLpoition of the orifice Il! and, since this portion has been madefso small as to prevent the glazingmaterial from flowingv therethrough, the :latter will become solidied in approximately the position as illustrated in Figures 4 andl 5,l

to form a seal closing the oriiceinto the blocka-nd causing asubatmcspheric conditioner high vacuum. to.be; created within the block. This subat mospheric condition within the block or;- the dead air space within each block serves as; an insulatingV medium against the transfer of either heat `or cold from one sidewall to the other.

When theblock is formed of porcelainclayn4 the high density of.y the block forming material. will preserve thevacuum within the-block ferait.

indelinite period. If, however, the block. is,- formed. of; a more porousl ceramic material, air; may enter through the pores thereof to the inf. terior of the block, but even in thislatter event, there is formed within-theinterior of the block a.

deadvair, space which functions as an insulating,

medium andwhile not as effective as a vacuum; still possesses very high insulating qualities. or thermal values.

If itis desired touse the blocks or portions thereof as a facing for a wall, the block, after',- being formed,A may besevered on the diagrammatic line'A-A of'Figure 5, and the projecting'A portions of the connecting walls, after the-block: hasbeen red, `form means for bondingA thefacingy with a plaster or cement coating as is- Com-- mon in connection with the layingl of,` tile; and need ynot be further described.

Referringv now toliigures and 7 of thedraw-4 ings, wherein a modified form of the invention is illustrated, a building block 2liv is shown par- 55 tiallyfin section and removed fromga, mold. They building block is somewhat similar to theymold... described in connection with the first species. of` the invention and which is, except forthe slight modifications: hereinafter noted, employed to'v .a formv the modified block. In the modified formv of the invention, it will be noted that inV places of thestuds I8, there has been provided inclines or tapers 2l. on allor at least the lowermost exeY tremities offthe flanges 2,2. These inclines inthe.,-

01 'Spudsf the glaze maybe extnded to the Very 65, present nstancepresent firing feet 23 upon which limits of the faces I5; and' since the spuds are of a height desirably o r approximately one and'A one-half; times the depth ofthe adjacent flange, the lowermost portion of thefl'ange.. Will be. re.

the blockresteduring theliring operationV of the block. When applying the glazing material to.Y theouter. surfaces. 240i the block, thermaterial isv not applied beyond or lower than approxiY tained in. anY elevated. position. relative to. the ml matelytheposition or location indicated at.25..in

sagger and thereby avoid any adherence be tween, the flanges or bloclr andthe saggel? dur.-` ingfthe ,-iiringA yoperation.l llhe ,Spuda as,V indicated, l'rereinabove,I are staggered, as most, clearly il,-v

Figures. 6. and 'LwhichVA will leave the balance-'cfrv the taperV or` incline unglaaed to thereby avoid.

adherence between the yblock and` sagger.

Inthe presentform. also the4 outer, surfaces;v

lustrated inliigure sothat they may not inter- 'U5 il!!A areofl pyramidal form, as clearly indicatedjn;

the drawings, which enhances the ornamental appearance of the block and, more specifically, materially increases the strength of or rigidiiies the block against not only service stresses, but also the atmospheric condition existing within the block.

If desired, outer surfaces of the connecting walls of both blocks may be provided with a sanded surface, as shown at 2'6 in Figure 7, which is common in connection with insulators. This surface `is formed by glazing the surface and, while the glazing material is in the moistened state, causing sand to engage with the surfaces to which it will adhere by reason of the adhesive qualities of the glazing material. When the block is red, owing to the fusion to the glaze, the sand is rmly connected to the walls and forms a bond for mortar or cement by which the blocks may be connected to form a wall or ceiling structure.

It will, of course, be noted that since the block is a product of casting, any configuration may be formed on the faces I5 of the first species of the invention, and 24 of the second species, and further, that various changes and alterations may be made to the illustrated and described construction without departing from within the spirit of the present invention and the scope of the appended claims.

I claim:

1. A method of forming a hollow building block of ceramic material employing a mold cf plaster of Paris or the like, having the walls conforming to the shape of the finished block and a filiing opening therein, comprising filling the mold cavity with iiuid ceramic material through said opening, allowing the material in contact with the walls of the mold to harden for a limited time, removing from the interior of the block the greater portion of unhardened fluid ceramic material through said opening, placing a plaster of Paris plug in said opening and causing the remaining fluid ceramic material to completely iill and harden in the opening in said block forming a, continuation of said lling opening, removing the block from the mold, permitting the block so formed to dry, and finally firing said block to vitrify the same.

2. The method of forming a hollow building block of ceramic material, employing a multipart closed mold of moisture-absorbent material having a filling opening therein, comprising lilling said mold with ceramic material in fluid form, allowing the ceramic material in proximity to the walls of the mold to harden, pouring out of said opening the greater portion of the remaining uid ceramic material, inserting in said opening a, plug of moisture-absorbent material, causing the remaining fluid ceramic material to completely fill and harden in the opening in said ceramic material forming a continuation of said opening in said mold, opening the mold, removing the block from the mold, permitting the block so formed to dry, adding a glazing material to opposite side faces thereof, and finally ring the block so formed to vitrify the same.

3. The method of forming a hollow building block of ceramic material with a dead air space lwithin the same, employing a multi-part closed mold of plaster of Paris or the like having a iilling opening, comprising filling the interior of the closed mold through said opening with fluid ceramic material, permitting the material adjacent the walls of said mold to harden to form a block having walls of substantially uniform thicknessV'removing through said opening the greater portion of the bulk of the unhardened ceramic material, plugging said opening and allowing the remaining unhardened ceramic material to completely close the opening in said block inserting a plaster of Paris plug in said opening, causing the remaining fluid ceramic material to completely fill and harden in the opening in said ceramic material forming a continuation of said opening in said mold removing the mold, forming an orifice in said block, permitting the block so formed to dry, applying glazing material to the opposite side walls and to the periphery of said oriice, and firing said block to vitrication whereby the glazing material lls and seals said orifice.

4. The method of forming a, hollow building block of ceramic material having a vacuum created in the interior thereof, employing a multipart closed mold of plaster of Paris or the like having a filling opening, comprising lling the closed mold through a suitable opening with uid ceramic material, permitting the material adjacent the walls of said mold to harden to form a block having walls of substantially uniform thickness, removing through said opening the greater portion of the bulk of the unhardened ceramic material, plugging said opening and allowing the remaining unhardened ceramic material to completely close the opening in said block inserting a plaster of Paris plug in said opening, causing the remaining uid ceramic material to completely fill and harden in the opening in said ceramic material forming a continuation of said opening in said mold removing the mold, forming an orice in said block, permitting the block so formed to dry, applying glazed material to the opposite side walls of the block and to the defining surface of said opening, and iiring said block to vitrification whereby the glazing material in said orifice fills and seals said orifice.

RUSSELL G. BELLEZZA.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 2,015,681 Kesty Oct. 1, 1935 2,070,672 Moczala Feb. 16, 1937 2,106,415 Purinton Jan. 25, 1938 2,224,488 Rendall Dec. 10, 1940 2,226,220 Cox Dec. 24, 1940 2,277,507 Benner et al Mar. 24, 1942 2,277,543 Downs Mar. 24, 1942 FOREIGN PATENTS Number Country Date 6,699 Great Britain A. D. 1914 479,157 Great Britain Feb. 1, 1938

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