Abstract: A mold assembly for manufacturing concrete blocks in an automated dry-cast block machine. The mold assembly includes a plurality of liner plates which together form a mold cavity, wherein at least one of the liner plates includes an internal network of shafts which is configured to receive and provide a flow path for heated fluid to pass through to heat the at least one liner plate.

Abstract: A block having a top surface, a bottom surface opposing the top surface, a front surface, a rear surface opposing the front surface, the front and rear surfaces extending between the top and bottom surfaces, a first side surface, a second side surface opposing the first side surface, the first and second side surfaces extending between the front and rear surfaces, and a set of at least three leveling pads extending from the rear surface.

Abstract: A mold assembly for use with an automated dry cast concrete machine including a plurality of mold cavities, each mold cavity formed by a plurality of liner plates, wherein at least one liner plate of each mold cavity is moveable between an extended position and a retracted position relative to an interior of the mold cavity. The mold assembly further includes a master bar in mechanical communication with the at least one moveable liner plate of each of the mold cavities, and an actuator configured to drive the master bar in a first direction and a second direction, which is opposite the first direction, to respectively direct movement of the at least one moveable liner plate of each of the mold cavities between the extended and retracted positions.

Abstract: A mold assembly for molding concrete blocks including at least one mold cavity including a plurality of liner plates forming sides walls of the mold cavity, wherein at least one of the liner plates is moveable between an extended position and a retracted position relative to an interior of the mold cavity. The mold assembly further includes a linear actuator having an actuator axis, a first drive linkage coupled to the linear actuator, and a second drive linkage coupled to the first drive linkage and positioned off-axis of the actuator axis and in mechanical communication with the at least one moveable liner plate, wherein the linear actuator provides forces in opposite directions along the actuator axis to the first drive linkage to drive the second drive linkage toward and away from the interior of the mold cavity to direct movement of the at least one moveable liner plate between the extended and retracted positions.

Abstract: A mold assembly for manufacturing dry-cast concrete blocks in an automated dry-cast block machine, the mold assembly a plurality of liner plates forming at least one mold cavity, each liner plate corresponding to a perimeter side of the mold cavity, wherein at least one of the liner plates is moveable toward and away from an interior of the mold cavity. A master drive element is routed about at least a portion of the perimeter sides of the mold cavity, including the perimeter side corresponding to the at least one moveable liner plate, and forming a continuous loop, wherein the master drive element is configured to be driven back and forth about the loop to provide a first linear force in a first direction and a second linear force in a second direction opposite the first direction substantially in parallel with each perimeter side along which the master drive element is routed.

Abstract: A method of operating a concrete block machine including filling a feedbox with dry cast concrete when the feedbox is at a retracted position, moving the feedbox from the retracted position to an extended position over an open top of a mold, the mold including at least one mold cavity, depositing dry cast concrete from the feedbox into the at least one mold cavity via the open top of the mold, moving the feedbox from the extended position to the retracted position after depositing the dry cast concrete in the at least one mold cavity, and controllably moving a moveable cutoff element of a cutoff bar coupled to the feedbox so as to adjust a distance between the moveable cutoff bar element and the top of the mold as the feedbox moves from the extended position to the retracted position such that the moveable cutoff bar element selectively removes varying amounts of the deposited dry cast concrete so that a depth of concrete remaining in a portion of the at least one mold cavity corresponding to the moveable cut

Abstract: A concrete block machine including a mold having at least one mold cavity, a feedbox driven back and forth between retracted and extended positions, wherein the feedbox is positioned over a top of the mold deposits concrete in the at least one mold cavity when at the extended position, a cutoff bar coupled to the feedbox and including a moveable cutoff element, and a drive system. The drive system is coupled to the moveable cutoff element and moves the moveable cutoff element to adjust a distance between the moveable cutoff element and the top of the mold as the feedbox is driven from the extended position to the retracted position such that the moveable cutoff element removes varying amounts of concrete deposited in the mold cavity so that a depth of concrete remaining in the mold cavity varies in a desired fashion in a direction of movement of the feedbox.

Abstract: A mold assembly for an automated dry-cast block machine including a mold cavity formed by a plurality of frame elements, and a moveable liner plate positioned within the mold cavity and having a first major surface facing an interior of the mold cavity and a second major surface opposite the first major surface and facing away from the interior of the mold cavity, the liner plate configured to be moved toward and away from an interior of the mold cavity. At least one heater element is coupled to the second major surface of the moveable liner plate, the heater element configured to move with the moveable liner plate and to maintain the first major surface at a desired temperature.

Abstract: A mold assembly for an automated dry-cast block machine including a mold cavity formed by at least one frame element having a plurality of guide holes therein, a moveable liner plate positioned within the mold cavity and having a plurality of non-driven guide posts configured to align with and slide within the plurality of guide holes within the at least one frame element, and a drive system coupled to the moveable line plate independent of the guide posts and configured to drive the moveable liner toward and away from an interior of the mold cavity.

Abstract: A mold assembly for molding concrete blocks including at least one mold cavity including a plurality of liner plates forming sides walls of the mold cavity, wherein at least one of the liner plates is moveable between an extended position and a retracted position relative to an interior of the mold cavity. The mold assembly further includes a linear actuator having an actuator axis, a first drive linkage coupled to the linear actuator, and a second drive linkage coupled to the first drive linkage and positioned off-axis of the actuator axis and in mechanical communication with the at least one moveable liner plate, wherein the linear actuator provides forces in opposite directions along the actuator axis to the first drive linkage to drive the second drive linkage toward and away from the interior of the mold cavity to direct movement of the at least one moveable liner plate between the extended and retracted positions.

Abstract: A dual-acting linear actuator including a hollow body and a stationary hollow rod. The stationary hollow rod includes a first rod segment separated from a second rod segment by a separator plate, the stationary hollow rod extending through the hollow body such that the separator plate forms a first chamber and a second chamber within the hollow body, wherein the first rod segment is configured to transmit a power medium to the first chamber to cause the hollow body to move along the stationary hollow rod toward the first rod segment and the second rod segment is configured to transmit the power medium to the second chamber to cause the hollow body to move along the stationary hollow rod toward the second rod segment.

Abstract: A mold assembly for an automated dry-cast block machine including a mold cavity formed by a plurality of frame elements, and a moveable liner plate positioned within the mold cavity and having a first major surface facing an interior of the mold cavity and a second major surface opposite the first major surface and facing away from the interior of the mold cavity, the liner plate configured to be moved toward and away from an interior of the mold cavity. At least one heater element is coupled to the second major surface of the moveable liner plate, the heater element configured to move with the moveable liner plate and to maintain the first major surface at a desired temperature.

Abstract: A mold assembly for use with an automated dry cast concrete machine including a plurality of mold cavities, each mold cavity formed by a plurality of liner plates, wherein at least one liner plate of each mold cavity is moveable between an extended position and a retracted position relative to an interior of the mold cavity. The mold assembly further includes a master bar in mechanical communication with the at least one moveable liner plate of each of the mold cavities, and an actuator configured to drive the master bar in a first direction and a second direction, which is opposite the first direction, to respectively direct movement of the at least one moveable liner plate of each of the mold cavities between the extended and retracted positions.

Abstract: A mold assembly for an automated dry-cast block machine including a mold cavity formed by at least one frame element having a plurality of guide holes therein, a moveable liner plate positioned within the mold cavity and having a plurality of non-driven guide posts configured to align with and slide within the plurality of guide holes within the at least one frame element, and a drive system coupled to the moveable line plate independent of the guide posts and configured to drive the moveable liner toward and away from an interior of the mold cavity.

Abstract: A mold assembly including a plurality of mold components configured to form a mold cavity having a desired shape, at least one of the mold components having a notch configured to form a set-back flange in a masonry block formed in the mold cavity, the notch having a depth. The mold assembly further includes a moveable flange plate and a drive assembly configured to extend the moveable flange plate into and retract the moveable flange plate from the notch within a desired range of distances so as to adjust the depth of the notch.

Abstract: A mold assembly for manufacturing concrete blocks and which is adapted for use in a concrete block machine. The mold assembly includes a plurality of liner plates forming at least a first mold cavity, wherein at least a first liner plate is moveable, and a drive assembly. The drive assembly includes a first drive element having a first end and coupled to the first moveable liner plate proximate to a second end, and an actuator assembly. The actuator assembly includes a second drive element selectively coupled to the first drive element proximate to the first end, wherein the actuator assembly is configured to drive the second drive element along a first axis so as to cause at least the second end of the first drive element to move along a second axis and cause the first moveable liner plate to move toward and away from an interior of the first mold cavity.

Abstract: A mold assembly for producing masonry blocks and adapted for use in a masonry block machine. The mold assembly includes a plurality of liner plates, each liner plate having a major surface, the liner plates positioned within a mold box and configured such that the major surfaces form a mold cavity having a desired form, wherein at least one of the liner plates is moveable between a retracted position and a desired extended position toward an interior of the mold cavity. A gear drive assembly selectively coupled to the at least one moveable liner plate and configured to move the at least one moveable liner plate between the retracted position and the extended position, wherein the gear drive assembly is positioned substantially external to the mold box when the at least one moveable liner plate is in the retracted position.

Abstract: One aspect of the present invention provides a mold assembly for manufacturing concrete blocks that is adapted for use in a concrete block machine. The mold assembly comprises a plurality of liner plates and a gear drive assembly. Each liner plate has a major surface and the liner plates are configured such that the major surfaces form a mold cavity, wherein at least one of the liner plates is moveable. The gear drive assembly is selectively coupled to the at least one moveable liner plate and is configured to move the at least one moveable liner plate in a first direction toward an interior of the mold cavity by applying a force in a second direction different from the first direction, and to move the liner plate in a direction away from the interior of the mold cavity by applying a force in a direction opposite the second direction.