Back to results
US 7,267,321 B1Granted
Wall block mold
OwnerKelly J. Morrellinventor
Life of this patent
Estimating the term…
Abstract
A system and method of forming differently sized and/or textured construction blocks from a single mold. The system includes a mold having a base and movable side walls that cooperate with the base to form a mold cavity, and one or more inserts that are configured to be positioned in the mold. The mold is arranged and oriented so that its side walls form the top, bottom, front, and rear surfaces of each block. The inserts may be used individually or grouped together into predetermined sets to form different blocks, such as interior and end blocks, as well as cap stones.
Claims26
A system for casting blocks, the system comprising:
- a mold comprising;
- a base having a plurality of edges;
- and,
- a plurality of side walls that correspond to the number of edges of the base and which intersect therewith, the base and side walls cooperating to form a cavity having a plurality of interior surfaces and an opening for receiving mold material;
- a first, movably positionable insert comprising a first surface, a second surface spaced from the first surface, and a plurality of side surfaces, the insert configured and arranged to be supported by the base, the insert selectively positionable in a generally vertical direction with respect to the base of the mold, with the insert configured to form one side surface of a block having a top surface, a bottom surface, a front surface, a rear surface, and two side surfaces;
- a second, reversibly positionable insert, with the second insert comprising a first surface, a second surface spaced from the first surface, and a plurality of side surfaces, with the first surface of the second insert having a first portion with a roughened, non-faceted cavity and a second portion that is generally smooth and planar, with the second insert configured to impart a roughened texture to a block when the second insert is in a first position, and with the second insert configured to impart a generally smooth and planar texture to a surface of a block when the second insert is in a second position;
- and
- a third, reversibly positionable insert, with the third insert comprising a first surface, a second surface spaced from the first surface, and a plurality of side surfaces, with the first surface of the third insert having a first portion with a roughened, non-faceted cavity and a second portion that is generally smooth and planar, with the third insert configured to impart a roughened texture to a block when the third insert is in a first position, and with the third insert configured to impart a generally smooth and planar texture to a surface of a block when the third insert is in a second position.
5 more elements
A mold used to manufacture a block having a front surface, a rear surface spaced from the front surface, a pair of opposed side surfaces extending between the front and rear surfaces, a top surface, and a bottom surface spaced from the top surface, the mold comprising:
- a base having a plurality of edges;
- a first side wall having an inwardly facing, longitudinal mold surface with a substantially planar central section that extends the length thereof, and with a first, inwardly facing longitudinal projection that extends the length thereof;
- a second side wall;
- a third side wall having an inwardly facing, longitudinal mold surface with a substantially planar central section that extends the length thereof, and with an outwardly facing longitudinal recess;
- a fourth side wall;
- and
- a first, reversibly positionable insert configured to be positioned against the second side wall, with the first insert having an inwardly facing first surface, an outwardly facing second surface, longitudinal side surfaces, and end surfaces, with the first surface of the first insert having a concavity that is configured to form a substantially convex front surface on a block formed by the mold, and with the second surface of the first insert configured to form a generally planar front surface on a block formed by the mold;
- with the first, second, third and fourth side walls intersecting the edges of the base and movable towards each other so that the base and the side walls form a mold cavity having an open top for receiving mold material;
- wherein the base forms one of the opposed side surfaces of a block, and wherein the first side wall, the first insert, the third side wall, and the fourth side wall form top, front, bottom and rear surfaces of the block.
6 more elements
A mold used to manufacture a block having a front surface, a rear surface spaced from the front surface, a pair of opposed side surfaces extending between the front and rear surfaces, a top surface, and a bottom surface spaced from the top surface, the mold comprising:
- a base having a plurality of edges;
- a first side wall having an inwardly facing mold surface that includes substantially planar central section that extends the length thereof and a first inwardly facing longitudinal projection that extends the length thereof;
- a second side wall;
- a third side wall having an inwardly facing mold surface that includes a substantially planar central section that extends the length thereof and an outwardly facing longitudinal recess;
- a fourth side wall;
- a first insert configured to be positioned adjacent the second side wall, with the first insert having an inwardly facing first surface, a second surface, longitudinal side surfaces, and end surfaces, and with the first surface of the first insert having a outwardly extending concavity that is curved between the longitudinal side surfaces and curved between the end surfaces;
- and
- a second insert configured to be positioned adjacent the fourth side wall, with the second insert having an inwardly facing first surface, a second surface, longitudinal side surfaces, and end surfaces, and with the first surface of the second insert having a outwardly extending concavity that is curved between the longitudinal side surfaces and curved between the end surfaces;
- with the outwardly extending cavity of the second insert being smaller than the outwardly extending cavity of the first insert;
- with the first, second, third and fourth side walls intersecting the edges of the base and movable towards each other so that the base and the side walls form a mold cavity having an open top for receiving mold material;
- wherein the base forms one of the opposed side surfaces of a block;
- wherein the first, and third, side walls form the top and bottom surfaces of a block;
- and
- wherein the first and second inserts form the front and rear surfaces of a block.
11 more elements
A system for casting blocks, the system comprising:
- a mold comprising:
- a base having a plurality of edges;
- a first elongated side wall;
- a second elongated side wall;
- a third elongated side wall;
- and
- a fourth elongated side wall;
- with the first, second, third and fourth elongated side walls intersecting the edges of the base and movable towards each other so that the base and the side walls form a mold cavity having an open top for receiving mold material;
- a first, movably positionable insert comprising a first surface, a second surface spaced from the first surface, and a plurality of side surfaces, the first insert configured and arranged to be supported by the base, the insert selectively positionable in a generally vertical direction with respect to the base of the mold, with the first insert configured to form one side surface of a block having a top surface, a bottom surface, a front surface, a rear surface, and two side surfaces;
- a second, reversibly positionable insert configured to be positioned adjacent the second elongated side wall with the second insert having an inwardly facing first surface, a second surface, longitudinal side surfaces, and end surfaces, and with the first surface of the second insert having a outwardly extending concavity that is curved between the longitudinal side surfaces and curved between the end surfaces, with the second insert configured to form the front surface of a block having a top surface, a bottom surface, a front surface, a rear surface, and two side surfaces;
- and
- a third, reversibly positionable insert configured to be positioned adjacent the fourth elongated side wall with the third insert having an inwardly facing first surface, a second surface, longitudinal side surfaces, and end surfaces, and with the first surface of the third insert having an outwardly extending concavity that is curved between the longitudinal side surfaces and curved between the end surfaces, with the concavity of the third insert being smaller than the concavity of the second insert, and with the third insert configured to form the rear surface of a block having a top surface, a bottom surface, a front surface, a rear surface, and two side surfaces;
- wherein the first, second, and third inserts form the side, front and rear surfaces of a block and wherein the first and third elongated side walls form the top and bottom surfaces of the block.
10 more elements
Dependencies are inferred from the claim text.