NESTED MASONRY BLOCK MANUFACTURING SYSTEM AND METHOD

Abstract

A masonry block set is disclosed that includes a first block having a first rectangular body and a first rectangular protrusion from a front face of the first rectangular body. A second block has a second rectangular body and a second rectangular protrusion from a front face of the second rectangular body. The first block and the second block can be combined to form a nested block pair where a front face of the first rectangular protrusion abuts the front face of the second rectangular body and a front face of the second rectangular protrusion abuts the front face of the first rectangular body.

Description

TECHNICAL FIELD

The present disclosure relates generally to masonry block manufacture, and more specifically to a nested masonry block manufacturing system and method.

BACKGROUND OF THE INVENTION

Masonry block manufacturing typically produces blocks that have a uniform appearance, but such blocks result in structures that lack desirable aesthetic features. However, manufacturing blocks with such desirable aesthetic features is typically more costly.

SUMMARY OF THE INVENTION

A masonry block set is disclosed that includes a first block having a first rectangular body and a first rectangular protrusion from a front face of the first rectangular body. A second block has a second rectangular body and a second rectangular protrusion from a front face of the second rectangular body. The first block and the second block can be combined to form a nested block pair where a front face of the first rectangular protrusion abuts the front face of the second rectangular body and a front face of the second rectangular protrusion abuts the front face of the first rectangular body.

Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings may be to scale, but emphasis is placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views, and in which:

FIG. 1 is a diagram of a nested masonry block design, in accordance with an example embodiment of the present disclosure;

FIG. 2 is a diagram of nested masonry blocks configured for splitting, in accordance with an example embodiment of the present disclosure;

FIG. 3 is a diagram of split nested masonry blocks, in accordance with an example embodiment of the present disclosure;

FIG. 4 is a diagram of a first alternative nested masonry block design, in accordance with an example embodiment of the present disclosure;

FIG. 5 is a diagram of a second alternative masonry block design, in accordance with an example embodiment of the present disclosure;

FIG. 6 is a diagram of a third alternative masonry block design, in accordance with an example embodiment of the present disclosure;

FIG. 7 is a diagram of a splitting assembly, in accordance with an example embodiment of the present disclosure;

FIG. 8 is a diagram of a process for splitting nested masonry blocks, in accordance with an example embodiment of the present disclosure;

FIG. 9 is a diagram of a masonry block, in accordance with an example embodiment of the present disclosure; and

FIG. 10 is a diagram of a split masonry block, in accordance with an example embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures may be to scale and certain components can be shown in generalized or schematic form and identified by commercial designations in the interest of clarity and conciseness.

The present disclosure is directed to a system and method for manufacturing nested blocks that have a different appearance from each other but which can be manufactured at a low cost. The nested blocks of the present disclosure can also be split, to create additional variations in appearance.

FIG. 1 is a diagram of a nested masonry block 100 design, in accordance with an example embodiment of the present disclosure. Nested masonry block 100 can be formed from cement, concrete, masonry, composite materials, clay, plaster or other suitable materials, and can be formed by wet casting, dry casting, molding, forming or other suitable processes.

Nested masonry blocks 100 include block 102 and block 104, which are configured to form a complementary nested pair. In one example embodiment, block 102 can include a projected feature having a length L1, and block 104 can include a projected feature having a length L2, where the sum of L1 and L2 equals the overall length of each of blocks 102 and 104. In another example embodiment, the sum of L1 and L2 can equal less than the overall length of each block, such as where a cut-out is used to modify the dimensions of each projected feature. An example of this cut-out is shown with dashed lines, but other suitable cut-out features can also or alternatively be used. Likewise, instead of a cut-out, the mold used to form blocks 102 and 104 can be configured to create projected features having lengths L1 and L2 that total less than the overall length of each block or can be configured in other suitable manners.

In one example embodiment, the mold used to form blocks 102 and 104 can be a dry cast mold that forms the blocks on a surface that allows the blocks to be nested for a subsequent splitting operation by pushing the blocks together. In this example embodiment, blocks 102 and 104 can be disposed as shown, so as to minimize the amount of additional handling that is needed. Alternatively, a plurality of blocks 102 can be formed using a first mold and a plurality of blocks 104 can be formed using a second mold, and blocks 102 and 104 can then be moved into a splitting assembly, or other suitable processes can also or alternatively be used.

FIG. 2 is a diagram of nested masonry blocks 200 configured for splitting, in accordance with an example embodiment of the present disclosure. Nested masonry blocks 200 includes block 102 abutting block 104, so as to allow a splitting device to be placed above split line 106. In this manner, the projected features of each of blocks 102 and 104 can be split in a single splitting operation. Nested masonry blocks 200 can be molded in a nested configuration, can be molded separately and moved into a nested configuration, or other suitable processes can also or alternatively be used. Split line 106 can be moved to the left or the right, can be angled (such as by rotating the splitting device or by rotating nested masonry blocks 200 relative to split line 106), or in other suitable manners.

FIG. 3 is a diagram of split nested masonry blocks 300, in accordance with an example embodiment of the present disclosure. Split nested masonry blocks 300 includes split masonry blocks 302 and 304 and end fragments 306 and 308, which remain after a splitting operation has been completed. Typically, the splitting operation will not separate blocks 302 and 304 and end fragments 306 and 308 as shown, which are shown separated for clarity. In one embodiment, block manufacturing equipment can be configured to separate blocks 302 and 304, such as by placing blocks 302 and 304 on separate adjacent plates and then by separating the plates after splitting, by using robotic manipulators or in other suitable manners.

FIG. 4 is a diagram of a first alternative nested masonry block 400 design, in accordance with an example embodiment of the present disclosure. Nested masonry block 400 can be formed from cement, concrete, masonry, composite materials, clay, plaster or other suitable materials, and can be formed by wet casting, dry casting, molding, forming or other suitable processes.

Nested masonry block 400 includes block 402 and block 404, where block 402 includes a rectangular inset and block 404 includes a corresponding rectangular protrusion. As with nested masonry block 100, the size of the rectangular protrusion of block 404 can be modified by cutting or molding the protrusion to a size that is smaller than the size of the rectangular inset. Likewise, other suitable rectangular inset and protrusion pairs can be used where suitable, or other shapes as disclosed herein or as may otherwise be suitable can be combined with the shapes shown in FIG. 4. Nested masonry block design 400 can be split in a manner similar to that shown for nested masonry blocks 200, where a split line can identify the location of a splitting blade that will create split blocks and fragments in the manner shown in FIG. 3 or in other suitable manners, such as where the split line is moved to the left or right, is angled or in other suitable manners.

FIG. 5 is a diagram of a second alternative masonry block 500 design, in accordance with an example embodiment of the present disclosure. Nested masonry block 500 can be formed from cement, concrete, masonry, composite materials, clay, plaster or other suitable materials, and can be formed by wet casting, dry casting, molding, forming or other suitable processes.

Nested masonry block 500 includes block 502 and block 504, where block 502 includes an arcuate face and block 504 includes a corresponding arcuate face. As with nested masonry block 100, the size of the arcuate faces of blocks 502 and 504 can be modified by cutting or molding the arcuate faces to a different size that does not match the other nested block. Likewise, other suitable arcuate faces can be used where suitable, or other shapes as disclosed herein or as may otherwise be suitable can be combined with the shapes shown in FIG. 5. Nested masonry block design 500 can be split in a manner similar to that shown for nested masonry blocks 200, where a split line can identify the location of a splitting blade that will create split blocks and fragments in the manner shown in FIG. 3 or in other suitable manners, such as where the split line is moved to the left or right, is angled or in other suitable manners.

FIG. 6 is a diagram of a third alternative masonry block 600 design, in accordance with an example embodiment of the present disclosure. Nested masonry block 600 can be formed from cement, concrete, masonry, composite materials, clay, plaster or other suitable materials, and can be formed by wet casting, dry casting, molding, forming or other suitable processes.

Nested masonry block 600 includes block 602 and block 604, where block 602 includes an angled face and block 604 includes a corresponding angled face. As with nested masonry block 100, the size of the angled faces of blocks 602 and 604 can be modified by cutting or molding the angled faces to a different size that does not match the other nested block. Likewise, other suitable angled faces can be used where suitable, or other shapes as disclosed herein or as may otherwise be suitable can be combined with the shapes shown in FIG. 6. Nested masonry block design 600 can be split in a manner similar to that shown for nested masonry blocks 200, where a split line can identify the location of a splitting blade that will create split blocks and fragments in the manner shown in FIG. 3 or in other suitable manners, such as where the split line is moved to the left or right, is angled or in other suitable manners.

FIG. 7 is a diagram of a splitting assembly 700, in accordance with an example embodiment of the present disclosure. Splitting assembly 700 includes top splitting assembly 702, support plate 704, left masonry block 706, right masonry block 708, splitting blade 710, left manipulator arm 712 and right manipulator arm 714, each of which can be fabricated from steel, carbon steel, stainless steel, metal alloys, composite materials, electrical actuator and control systems, hydraulic actuator and control systems, other suitable components or a suitable combination of components. Splitting assembly 700 further includes controller 716 and sensors 718, which can be implemented in hardware or a suitable combination of hardware and software.

Top splitting assembly 702 can be fabricated from steel or other suitable materials as listed herein, and can be part of a hydraulic splitting press, an electric splitting press or other suitable components. Top splitting assembly 702 can be configured to detect when left masonry block 706 and right masonry block 708 are in location, and to automatically cause splitting blade 710 to apply a force to a predetermined split line. Top splitting assembly 702 can be configured to controllably shift left or right, to rotate or to move in other manners to facilitate the splitting operation.

Support plate 704 can be fabricated from steel or other suitable materials as listed herein, and can be a support plate having an internal mechanism to accommodate splitting blade 710 as shown, multiple separate support plates that include a splitting blade in between and which can be moved as needed to place left masonry block 706 and right masonry block 708 in contact or to separate the blocks after splitting, to dispose of end fragments, or can have other suitable configurations. In configurations where support plate 704 provides a block or end fragment movement function, support plate 704 can utilize one or more of sensors 718 to detect when a block is in place or has been split, can be powered by a hydraulic or electric driver or can have other suitable controllable functionality as discussed further herein.

Left masonry block 706 can be formed as discussed herein and can be placed on support plate 704 as part of the manufacturing process, such as where support plate 704 is the base plate during a molding operation. In another example embodiment, left masonry block 706 can be transported to support plate 704 on a conveyor belt or other suitable systems and can be moved onto support plate 704 by suitable electrical or hydraulic manipulators, where one or more of sensors 718 can be used to control the timing and operation of the manipulators.

Right masonry block 708 can be formed as discussed herein and can be placed on support plate 704 as part of the manufacturing process, such as where support plate 704 is the base plate during a molding operation. In another example embodiment, right masonry block 708 can be transported to support plate 704 on a conveyor belt or other suitable systems and can be moved onto support plate 704 by suitable electrical or hydraulic manipulators, where one or more of sensors 718 can be used to control the timing and operation of the manipulators.

Splitting blade 710 can be formed from alloyed steel and can be configured to split masonry blocks, such as by having a predetermined splitting angle of the blade, one or more protrusions on the blade for creating a textured appearance or other suitable configurations. In one example embodiment, splitting blade 710 can be configured to be quickly removed and replaced, to allow splitting blade 710 to be quickly replaced in the field after it has performed a predetermined number of splitting operations or in other suitable manners. As shown, splitting blade 710 can include top and bottom components, where the top component is moved by top splitting assembly 702 and where the bottom component is moved by support plate 704, or in other suitable manners.

Left manipulator arm 712 and right manipulator arm 714 can be fabricated from steel or other suitable materials, and can operate under electrical or hydraulic control to place left masonry block 706 and right masonry block 708 in contact, to separate left masonry block 706 and right masonry block 708 after splitting and for other suitable functions. In one example embodiment, left manipulator arm 712 and right manipulator arm 714 can be operated by controller 716 in response to sensor data, such as to control an amount and direction of force that is applied to left masonry block 706 and right masonry block 708.

Controller 716 can be implemented as one or more algorithms that operate in conjunction with one or more processors, such as algorithms implemented in code that are stored in a data memory device and which are installed in a working memory of the one or more processors to cause the one or more processors to control the operation of splitting assembly 700. In one example embodiment, controller 716 can be coupled to top splitting assembly 702, support plate 704, left manipulator arm 712, right manipulator arm 714, sensors 718 and other system components to allow the operation of the system components to be controlled to move and split left masonry block 706 and right masonry block 708, to remove the split blocks and fragments, and for other suitable purposes as discussed further herein.

Sensors 718 can include optical sensors, pressure sensors, weight sensors, range of motion sensors or other suitable sensors needed for the control and operation of splitting assembly 700. In one example embodiment, sensors 718 can be provided in conjunction with one or more of top splitting assembly 702, support plate 704, left manipulator arm 712, right manipulator arm 714 or other associated system components, and controller 716 can be configured to read data from each sensor and to process the data to support operations of splitting assembly 700, or for other suitable purposes such as those discussed herein.

In operation, splitting assembly 700 allows nested blocks to be moved into position and split, and further allows the split blocks, end fragments and other process by-products to be removed, to clear splitting assembly 700 for continuous operation.

FIG. 8 is a diagram of a process 800 for splitting nested masonry blocks, in accordance with an example embodiment of the present disclosure. Process 800 can be implemented using programmable controllers of a splitting assembly and the associated components of the splitting assembly, or using other suitable systems and components.

Process 800 begins at 802, where complementary masonry block halves are moved to a splitting assembly press. In one example embodiment, the block halves can be separately formed and moved on a conveyor after removal from a mold. In this example embodiment, the block halves can be formed on a plate that will provide the base during the splitting operation, or other suitable processes can also or alternatively be used. For example, manipulators can be used to place the blocks on the conveyor or the blocks can be formed in a mating configuration, to reduce the amount of post molding handling that is needed. The process then proceeds to 804.

At 804, the masonry block halves are pushed together. In one example embodiment, controllable manipulators can be used to apply a predetermined force to the side of the block halves, roller wheels can be operated to move the block halves towards each other or other suitable processes can also or alternatively be used. The process then proceeds to 806.

At 806, the assembly of block halves is aligned with a splitting blade. In one example embodiment, the splitting blade can be located in a predetermined position relative to the configuration of the assembled block halves, the splitting blade can be moved in response to sensor data identifying boundaries of the assembled block halves or other suitable processes can also or alternatively be used. The process then proceeds to 808.

At 808, the block halves are split. In one example embodiment, the splitting process can include applying a predetermined force to a splitting blade, applying an increasing amount of force until a sudden decrease in resistance is measured, or in other suitable manners. The process then proceeds to 810.

At 810, the split block halves are removed. In one example embodiment, each block half can be removed using rollers, a manipulator or in other suitable manners. The process then proceeds to 812.

At 812, the split caps are separated from the blocks halves. In one example embodiment, the split caps can remain on a splitting surface after the block halves are removed, and a brush or other suitable device can be used to move the split caps to a receptacle or other suitable locations. The process then repeats.

In operation, process 800 allows a continuous splitting operation for complementary masonry blocks to be performed. Process 800 allows mating masonry block halves to be assembled prior to splitting, in addition to allowing the split blocks to be removed after splitting.

FIG. 9 is a diagram of a masonry block 900, in accordance with an example embodiment of the present disclosure. Masonry block 900 has a first width 902 of a protruding front feature, a second width 904 of a recessed front feature, a feature height 908, a major depth 910 and a minor depth 906, which generally define the size of block 900. The first width 902 is larger than the second width 904 as shown, but the relationship between the widths can be reversed, such as in a matching complementary block that will be combined with block 900 for shipping or splitting. A top feature extends slightly above feature height 908 to provide a false gap between blocks when stacked, but the top feature can be omitted where suitable. The major depth 910 is larger than the minor depth 906, and the ratio of the two depths can be adjusted as needed.

FIG. 10 is a diagram of a split masonry block 1000, in accordance with an example embodiment of the present disclosure. Masonry block 1000 has a first width 1002 of a protruding front feature, a second width 1004 of a recessed front feature, a feature height 1008, a major depth 1010 and a minor depth 1006, which generally define the size of block 1000. The first width 1002 is larger than the second width 1004 as shown, but the relationship between the widths can be reversed, such as in a matching complementary block that will be combined with block 1000 for shipping or splitting. A top feature extends slightly above feature height 1008 to provide a false gap between blocks when stacked, but the top feature can be omitted where suitable. The major depth 1010 is larger than the minor depth 1006, and the ratio of the two depths can be adjusted as needed.

The present disclosure includes a set of masonry blocks, such as masonry blocks formed from dry cast concrete or other suitable materials. Each block has a height H between parallel top and bottom surfaces, and a width W, which can be selected between 5H to 10H between parallel left and right surfaces. The left and right surfaces can be perpendicular to flat top and bottom surfaces, to allow the blocks to be used for pavers, walls or other assemblies. A rear surface can be perpendicular to the top, bottom, left, and right surfaces. A protruding front surface can be parallel to the rear surface and can have a depth Dp in front of the rear surface, where Dp is between 0.4 W and 0.5 W. The width Wp of the protruding front surface Wp can be less than W, and a recessed front surface can be provided that is parallel to the rear surface. A depth Dr of the block between the recessed surface and the rear surface can be between 0.3 W and Dp. The width of the recessed surface Wr can equal W−Wp.

In another example embodiment, a set of blocks can include a first block where Wp<Wr and a second block where Wp>Wr. In addition or alternatively, the set of blocks can include a first block where Wp=2Wr and a second block where Wp=0.5Wr.

In addition or alternatively, the set of blocks can includes a first block where Wp is less than or equal to Wr of the second block, and a second block where Wp is less than or equal to Wr of the first block. The protruding front surfaces can be split or molded, the rear surface of one block can have a false joint and the rear surface of second block can have no false joint, a raised portion on the top surface can be used to create a joint when the blocks are stacked, and other suitable configurations can also or alternatively be provided.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.”

As used herein, “hardware” can include a combination of discrete components, an integrated circuit, an application-specific integrated circuit, a field programmable gate array, or other suitable hardware. As used herein, “software” can include one or more objects, agents, threads, lines of code, subroutines, separate software applications, two or more lines of code or other suitable software structures operating in two or more software applications, on one or more processors (where a processor includes one or more microcomputers or other suitable data processing units, memory devices, input-output devices, displays, data input devices such as a keyboard or a mouse, peripherals such as printers and speakers, associated drivers, control cards, power sources, network devices, docking station devices, or other suitable devices operating under control of software systems in conjunction with the processor or other devices), or other suitable software structures. In one exemplary embodiment, software can include one or more lines of code or other suitable software structures operating in a general purpose software application, such as an operating system, and one or more lines of code or other suitable software structures operating in a specific purpose software application. As used herein, the term “couple” and its cognate terms, such as “couples” and “coupled,” can include a physical connection (such as a copper conductor), a virtual connection (such as through randomly assigned memory locations of a data memory device), a logical connection (such as through logical gates of a semiconducting device), other suitable connections, or a suitable combination of such connections. The term “data” can refer to a suitable structure for using, conveying or storing data, such as a data field, a data buffer, a data message having the data value and sender/receiver address data, a control message having the data value and one or more operators that cause the receiving system or component to perform a function using the data, or other suitable hardware or software components for the electronic processing of data.

In general, a software system is a system that operates on a processor to perform predetermined functions in response to predetermined data fields. A software system is typically created as an algorithmic source code by a human programmer, and the source code algorithm is then compiled into a machine language algorithm with the source code algorithm functions, and linked to the specific input/output devices, dynamic link libraries and other specific hardware and software components of a processor, which converts the processor from a general purpose processor into a specific purpose processor. This well-known process for implementing an algorithm using a processor should require no explanation for one of even rudimentary skill in the art. For example, a system can be defined by the function it performs and the data fields that it performs the function on. As used herein, a NAME system, where NAME is typically the name of the general function that is performed by the system, refers to a software system that is configured to operate on a processor and to perform the disclosed function on the disclosed data fields. A system can receive one or more data inputs, such as data fields, user-entered data, control data in response to a user prompt or other suitable data, and can determine an action to take based on an algorithm, such as to proceed to a next algorithmic step if data is received, to repeat a prompt if data is not received, to perform a mathematical operation on two data fields, to sort or display data fields or to perform other suitable well-known algorithmic functions. Unless a specific algorithm is disclosed, then any suitable algorithm that would be known to one of skill in the art for performing the function using the associated data fields is contemplated as falling within the scope of the disclosure. For example, a message system that generates a message that includes a sender address field, a recipient address field and a message field would encompass software operating on a processor that can obtain the sender address field, recipient address field and message field from a suitable system or device of the processor, such as a buffer device or buffer system, can assemble the sender address field, recipient address field and message field into a suitable electronic message format (such as an electronic mail message, a TCP/IP message or any other suitable message format that has a sender address field, a recipient address field and message field), and can transmit the electronic message using electronic messaging systems and devices of the processor over a communications medium, such as a network. One of ordinary skill in the art would be able to provide the specific coding for a specific application based on the foregoing disclosure, which is intended to set forth exemplary embodiments of the present disclosure, and not to provide a tutorial for someone having less than ordinary skill in the art, such as someone who is unfamiliar with programming or processors in a suitable programming language. A specific algorithm for performing a function can be provided in a flow chart form or in other suitable formats, where the data fields and associated functions can be set forth in an exemplary order of operations, where the order can be rearranged as suitable and is not intended to be limiting unless explicitly stated to be limiting.

It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.

Claims

1. A masonry block set comprising:

a first block having a first rectangular body and a first rectangular protrusion from a front face of the first rectangular body;

a second block having a second rectangular body and a second rectangular protrusion from a front face of the second rectangular body; and

wherein the first block and the second block can be combined to form a nested block pair where a front face of the first rectangular protrusion abuts the front face of the second rectangular body and a front face of the second rectangular protrusion abuts the front face of the first rectangular body.

2. The masonry block set of claim 1 wherein the first rectangular protrusion comprises a split surface.

3. The masonry block set of claim 1 wherein the front face of the first rectangular protrusion comprises a split surface.

4. The masonry block set of claim 1 wherein the nested block pair comprises a split extending through the first rectangular protrusion and the second rectangular protrusion.

5. The masonry block set of claim 1 wherein the first rectangular body and the second rectangular body have a first predetermined length, the first rectangular protrusion has a second predetermined length, the second rectangular protrusion has a third predetermined length, and the first predetermined length equals a sum of the second predetermined length and the third predetermined length.

6. The masonry block set of claim 1 wherein the first rectangular body and the second rectangular body have a first predetermined length, the first rectangular protrusion has a second predetermined length, the second rectangular protrusion has a third predetermined length, and the first predetermined length is greater than a sum of the second predetermined length and the third predetermined length.

7. The masonry block set of claim 1 wherein the first rectangular body and the second rectangular body have a first predetermined length.

8. The masonry block set of claim 7, wherein the first rectangular protrusion has a second predetermined length.

9. The masonry block set of claim 8, wherein the second rectangular protrusion has a third predetermined length.

10. The masonry block set of claim 9, wherein the first predetermined length is greater than a sum of the second predetermined length and the third predetermined length.

11. A method of manufacturing a masonry block set comprising:

forming a first block having a first rectangular body and a first rectangular protrusion from a front face of the first rectangular body;

forming a second block having a second rectangular body and a second rectangular protrusion from a front face of the second rectangular body; and

combining the first block and the second block to form a nested block pair where a front face of the first rectangular protrusion abuts the front face of the second rectangular body and a front face of the second rectangular protrusion abuts the front face of the first rectangular body.

12. The method claim 11 further comprising splitting the first block.

13. The method of claim 11 further comprising splitting the second block.

14. The method of claim 11 further comprising splitting the first rectangular protrusion and the second rectangular protrusion in a single splitting operation.

15. The method of claim 11 wherein the first rectangular body and the second rectangular body have a first predetermined length, the first rectangular protrusion has a second predetermined length, the second rectangular protrusion has a third predetermined length, and the first predetermined length equals a sum of the second predetermined length and the third predetermined length.

16. The method claim 11 wherein the first rectangular body and the second rectangular body have a first predetermined length, the first rectangular protrusion has a second predetermined length, the second rectangular protrusion has a third predetermined length, and the first predetermined length is greater than a sum of the second predetermined length and the third predetermined length.

17. The method of claim 11 wherein the first rectangular body and the second rectangular body have a first predetermined length.

18. The method of claim 17, wherein the first rectangular protrusion has a second predetermined length.

19. The method of claim 18, wherein the second rectangular protrusion has a third predetermined length.

20. The method of claim 19, wherein the first predetermined length is greater than a sum of the second predetermined length and the third predetermined length.