US 8,133,337 B2 · Method for making a concrete block

Abstract

A mold core with a plurality of tension springs is placed in a mold box such that the top of the mold core is even with the top of the mold box when the plurality of tension springs have no tension. Block mix including a substantial amount of compressible material is poured into the mold and lightly vibrated. A movable bottom plate then moves downward at the same time as the mold core is moved downward a first distance to stretch the plurality of tension springs. After the mold core is moved downward the first distance, the movement of the mold core stops while the movement of the movable plate continues downward, thereby ejecting the partial block element from the mold. Block elements are cured, then glued together to form a complete block. One or both of the exterior surfaces of the block may have a wooden attachment layer attached.

Claims20

Dependent claims

A method for making a concrete block comprising the steps of:

(A) mixing cement, water and compressive material in first proportions;
(B) conveying the mixture in step (A) to a molding machine;
(C) pouring the mix conveyed in step (B) into a mold comprising a mold box having an open bottom with a movable plate positioned at the bottom of the mold box, and a mold core having a plurality of tension springs that position a top of the mold core at a top of the mold box when the plurality of tension springs are not under tension, the mold core defining a plurality of regions in the mold box that will not receive the mix;
(D) vibrating the mix in the mold to form a partial block element that has a shape defined by the mold box and the mold core;
and
(E) moving the movable plate downward while pushing downward on the mold core to stretch the plurality of tension springs a first distance, the movable plate continuing a downward movement after the mold core has traveled the first distance until the partial block element is clear from the mold box.

3 more elements

A method for making a concrete block comprising the steps of:

(A) mixing cement, water and expanded polystyrene foam beads with a diameter from ⅛ inch (3.2 mm) to ⅜ inch (9.5 mm) in first proportions;
(B) conveying the mixture in step (A) to a molding machine;
(C) pouring the mix conveyed in step (B) into a mold comprising a mold box, a movable plate at the bottom of the mold box, and a mold core having a plurality of tension springs that position a top of the mold core at a top of the mold box when the plurality of tension springs are not under tension;
(D) vibrating the mix in the mold to form a partial block element that has a shape defined by the mold box and the mold core;
(E) moving the movable plate downward while pushing downward on the mold core to stretch the plurality of tension springs a first distance, the movable plate continuing a downward movement after the mold core has traveled the first distance, thereby ejecting the block element from the mold box;
(F) curing the partial block element;
and
(G) coupling together with adhesive a plurality of partial block elements and coupling with adhesive a wooden sheet to at least one of the plurality of partial block elements to form a completed block having at least one surface substantially covered with a wooden attachment layer.

5 more elements

Dependencies are inferred from the claim text.

Method for making a concrete block

Life of this patent

Method for making a concrete block

Life of this patent

Abstract

Claims20