Method of making a concrete block
AssigneeAnchor Wall Systems, Inc.
InventorRonald J. Scherer
Life of this patent
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Abstract
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.
Claims9
A process for producing a concrete block having upper and lower faces, a front face, a rear face, and opposed side faces, the method comprising the steps of:
- providing a mold having a plurality of side walls defining a mold cavity with an open top and an open bottom;
- positioning a pallet having a flat surface underneath the mold to temporarily close the entire open bottom of the mold cavity with the flat surface of the pallet;
- introducing dry cast concrete into the mold cavity through the open mold top;
- compacting the dry cast concrete to form a pre-cured concrete block with the rear face of the block resting on the pallet and the front face of the block facing upward, the compacting including introducing a stripper shoe having a face that comprises a mirror image of a three-dimensional pattern that simulates natural stone into the mold cavity through the open top of the mold cavity, the three-dimensional pattern having a maximum relief of at least about 0.5 inch;
- pressing the patterned face of the stripper shoe against the dry cast concrete contained in the mold cavity, to impart a pattern that simulates natural stone to the front face of the pre-cured concrete block with a maximum relief of at least about 0.5 inch;
- reopening the temporarily-closed bottom of the mold cavity;
- discharging the pre-cured concrete block from the mold cavity through the reopened bottom of the mold cavity;
- and
- curing the pre-cured concrete block.
Dependencies are inferred from the claim text.