Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – Forming plural articles
Reexamination Certificate
1998-07-06
2001-11-27
Silbaugh, Jan H. (Department: 1732)
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
Forming plural articles
C264S071000, C264S157000, C264S333000, C425S253000, C425S414000, C425S452000, C425S468000, C249S052000, C405S286000
Reexamination Certificate
active
06322742
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates generally to a method of preparing stackable block structures from raw concrete mixes, and more particularly to such a method for forming block structures wherein the individual blocks are formed in a mold box with the sides of the block being positioned along the upper and lower surfaces of the mold box. More particularly, the method of the present invention relates to such an assembly process wherein articulated core bars are introduced and removed from the mold box along an axis formed parallel to the bottom surface of the mold box and parallel to the surface of the conveyor upon which the blocks are formed. Stackable blocks prepared in accordance with the present invention are processed expeditiously and find wide application in the creation and erection of retaining walls, as well as for general building purposes.
In the past, concrete blocks and stackable block structures in particular have typically been formed from raw concrete mixes compressed and formed or otherwise configured within a mold box. These mold boxes have frequently been supported or otherwise positioned on the surface of a moving conveyor wherein various operations are undertaken in the process of formation and creation of the blocks. In order to fabricate stackable block structures with a configuration including a hollow core, core rods have been utilized which are typically articulated along an axis perpendicular or normal to the surface of the supporting conveyor belt, and with the supporting surface of the conveyor belt in direct contact with the surface of the block which becomes the top or the bottom. Such processes are relatively straightforward when conventional blocks are being formed, however when blocks having winged or flanged protrusions along one of their surfaces, these typical processes and/or procedures become difficult to undertake on a continuous and/or automatic basis. The present invention utilizes a process and technique which departs from the typical operations described above, and at the same time, makes it possible to continuously and/or automatically produce blocks which are formed with wing portions and/or flanges along the rear face thereof.
SUMMARY OF THE INVENTION
In accordance with the present invention, the stackable block structures are formed utilizing a mold box in which the individual block structures are fabricated on their sides. In other words, the supporting surface of the conveyor belt makes contact with the first of the two opposed side surfaces of the blocks being formed thereon, thereby making it possible for core rods to be articulated along axes which are parallel to the surface of the conveyor belt, and also to the direction of belt travel. Additionally, blocks may be made in mold boxes on a two-up basis, with the orientation of the blocks being such that handling or positioning of the blocks during the unloading process will dispose or position the blocks in a position ready for splitting and/or cleaving along the mid-section to form a pair of substantially identical block elements. When fabricated in this fashion, a more rapid and/or continuous production operation is facilitated, and with post-cure handling and processing of the blocks being substantially expedited. In the actual steps or operations of the process, core rods are introduced horizontally along and through the base of the mold box, and a raw concrete mix of predetermined composition and consistency is introduced into the mold box. Thereafter, with the amount of concrete mix being appropriately metered, a reciprocatory block-configuring shoe is pressed downwardly onto the upper surface of the raw concrete mix in order to configure what ultimately becomes the second of the two opposed side surfaces or walls of the block.
In accordance with the technique of the present invention, block structures may be expeditiously formed continuously on a moving conveyor, and wherein the blocks are formed on their side surfaces, and wherein the finished blocks have a modified trapezoidal configuration tapering from front to rear and with laterally extending flanged wings defining a generally rectangular rear face. Such blocks have been found to have a configuration highly desirable for the fabrication of mortar-free structures, such as retaining walls, with the winged configuration being particularly useful in facilitating the formation of arcuate or curved walls. These walls are made possible by striking or breaking away the laterally extending flanged wing or wings of adjacent blocks to form a block with a fully trapezoidal configuration in plan view thus giving rise to ease of creation of desired orientation of individual blocks forming the retaining wall.
Therefore, it is a primary object of the present invention to provide an improved method of preparing stackable block structures from raw concrete mixes wherein the mold boxes are arranged so that the blocks being formed are positioned on their side surfaces, thereby making it possible to fabricate a block with a modified trapezoidal and winged configuration which tapers from front to rear while having laterally extending flanged wings forming the rear face or surface of the block.
It is yet a further object of the present invention to provide an improved method of preparing stackable block structures from raw concrete mixes wherein the block structures formed have a configuration which is trapezoidal tapering from front to rear, along with laterally extending flanged wings defining a generally rectangular rear face.
Other and further objects of the present invention will become apparent to those skilled in the art upon a study of the following specification, appended claims, and accompanying drawings.
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Allan Block Corporation
Haugen Law Firm PLLP
Poe Michael I.
Silbaugh Jan H.
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