Method for making and treating wall blocks
AssigneeKeystone Retaining Wall Systems, Inc.
InventorsAntal Z. Suto, John A. Campau, John Daniel Campau, Donald L. Reuschel, Robert A. MacDonald
Life of this patent
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Abstract
A method for treating the surfaces and edges of a block to mimic the appearance of natural stone. The apparatus and method can treat up to four sides of a block, can be adjusted to provide varying degrees of surface and edge treatment, and useful in high volume block production equipment. Blocks are produced having a natural, weathered appearance without the damage, breakage, dust, or expense associated with conventional splitting and tumbling methods.
Claims55
A method for treating the surface of a block, the block having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the method comprising:
- positioning the block in a first treatment station including an edge rounding member;
- treating the block in the first treatment station to simultaneously round the upper and lower face edges of the first and second opposed faces of the block;
- positioning the block in a second treatment station including a surface roughening member;
- and
- treating the block in the second treatment station to roughen a surface of at least one of the first and second opposed faces.
A meted for treating the surface of a block, the block having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the method comprising:
- positioning the block in a first hammer station;
- treating the block in the first hammer station to simultaneously round the upper and lower face of edges of the first and second opposed faces the block;
- positioning the block in a first flail station;
- and
- treating the block in the first flail station to roughen a surface of at least one of the first and second opposed faces.
A method of making wall blocks, the blocks each having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the method comprising:
- forming the blocks in a mold;
- removing the blocks from the mold;
- positioning at least one of the blocks in a first treatment station;
- and
- simultaneously rounding the upper and lower face edges of the first and second opposed faces of the at least one block in the first treatment station without tumbling the at least one block together with other blocks in a block tumbler.
A method of making wall blocks, the blocks each having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the method comprising:
- forming the blocks in a mold;
- removing the blocks from the mold;
- positioning the blocks in a first treatment station including an edge rounding member;
- simultaneously rounding the upper and lower face edges of the first and second opposed faces of the blocks in the first treatment station;
- positioning the blocks in a second treatment station including a surface roughening member;
- and
- roughening the first and second opposed faces in the second treatment station.
A method of making wall blocks, the blocks each having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces to form upper and lower surface edges, the method comprising:
- forming the blocks in a mold which imparts a roughened surface texture to at least one of the first and second opposed faces of the blocks;
- removing the blocks from the mold;
- positioning at least one of the blocks in a first treatment station;
- and
- simultaneously rounding the upper and lower face edges of the first and second opposed faces in the first treatment station without tumbling the at least one block together with other blocks in a block tumbler.
A method of making wall blocks, the blocks each having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the method comprising:
- forming the blocks in a mold which imparts a roughened surface texture to at least one of the faces of the first and second opposed faces of the blocks;
- removing the blocks from the mold;
- positioning at least one of the blocks in a first treatment station including an edge rounding member;
- simultaneously rounding the upper and lower face edges of the first and second opposed faces of the at least one block having a roughened surface texture in the first treatment station without tumbling the at least one block together with other blocks in a block tumbler;
- positioning the at least one block in a second treatment station including a surface roughening member;
- and
- further roughening the surfaces of the first and second opposed faces in the second treatment station.
Dependencies are inferred from the claim text.