Method of making a concrete block

摘要

Molds and processes that permit high-speed, mass production of retaining wall blocks having patterned or other processed front faces, as well as retaining wall blocks formed by such processes. The invention permits the front face of the block to be impressed with a pattern or otherwise directly processed, to allow the formation of pre-determined block front faces, while at the same time facilitating high-speed, high-volume production of blocks. A mirror image of the desired pattern can be created on a stripper shoe by selecting a desired three-dimensional surface from a naturally occurring or man made object and digitally scanning the selected three-dimensional pattern to create scanned data. The scanned data can then be used to machine a face of the stripper shoe that is the mirror image of the selected pattern.

主权项

1. A method of making a concrete block having a three-dimensional patterned face as a front face in use; the method comprising the steps of:
(a) providing a mold having a plurality of side walls defining a mold cavity; the mold including: an open mold top, an open mold bottom closed by a pallet having an entirely flat surface closing the open mold bottom; and a mold surface having a three-dimensional pattern thereon, and a maximum relief, in the three-dimensional pattern, of at least about 0.5 inch;
the mold surface, of the mold provided, having a three-dimensional pattern resulting from: selection of a three-dimensional pattern of one or more existing objects; digital scanning of the selected three-dimensional pattern to create scanned data in XYZ coordinates that is representative of the selected three-dimensional pattern; creation, from the scanned data in the XYZ coordinates, of a digital data set that is representative of a desired three-dimensional patterned face based on the scanned data; and, use of the digital data set to create the mold surface as a mirror image of the desired block face; (b) introducing dry cast concrete into the mold cavity through the open top of the mold; (c) molding a pre-cured block in the mold by pressing a stripper shoe downwardly through the open top of the mold into the dry cast concrete, with the front face of the pre-cured block in use facing upward; the stripper shoe comprising the mold surface having the three-dimensional pattern thereon with a mirror image of the three-dimensional patterned face to form the pre-cured concrete block with the mold surface having the mirror image of the desired block face forming the desired three-dimensional patterned face on the pre-cured block;
(i) the pre-cured concrete block, in use, including a rear face opposite the three-dimensional patterned face, an upper face, a lower face opposite the upper face, opposite side faces in extension across the entire distance from adjacent the three-dimensional patterned face thereon to the rear face; (d) discharging the pre-cured block from the mold cavity onto the flat surface of the pallet; and (e) curing the pre-cured concrete block.