CONCRETE BLOCKS WITH NON-GEOMETRIC FACE SURFACES
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.
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.
SUMMARY OF THE INVENTIONIn 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.
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.
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. When used to construct walls, 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. In an alternative embodiment, 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. In another alternative embodiment, 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. As can best be seen in
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
The longitudinal side panels 160 of the embodiment of
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 generally vertical portion 140. When these blocks are used to form a wall, 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. In the embodiment shown in
In this embodiment the 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. 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 the block 50 and then assist in the removal of the formed blocks from the mold.
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. In other words, if one were to segment the divider 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 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. In some embodiments, the non-geometric pattern 20 formed on the face surface 10 may resemble a naturally occurring stone.
In the embodiment shown in
The block of
The block of
The block of
The block of
The block of
The block of
In
In the exemplary collection of blocks of
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
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
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.
Type: Application
Filed: Jun 26, 2007
Publication Date: Jan 1, 2009
Inventors: Timothy A. Bott (Sunfish Lake, MN), Robert A. Gravier (Edina, MN)
Application Number: 11/768,664
International Classification: E04B 2/08 (20060101);