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 proc
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.
대표청구항▼
What is claimed is: 1. A method of making a plurality of concrete blocks having different three dimensional patterned faces, comprising the steps of: selecting a plurality of different three-dimensional patterns of one or more existing objects; digitally scanning the different selected three-dimens
What is claimed is: 1. A method of making a plurality of concrete blocks having different three dimensional patterned faces, comprising the steps of: selecting a plurality of different three-dimensional patterns of one or more existing objects; digitally scanning the different selected three-dimensional patterns to create different scanned data in XYZ coordinates that is representative of each of the different selected three-dimensional patterns; creating from each of the different scanned data in the XYZ coordinates a different digital data set for each of the different three-dimensional patterns, the digital data sets being representative of the plurality of different desired three dimensional patterned faces of the concrete blocks based on the scanned data of the different three-dimensional patterns; using the digital data set for each of the different three-dimensional patterns to create a plurality of different mold surfaces each having a three-dimensional pattern that is the mirror image of one of the plurality of different desired three dimensional patterned concrete block faces, each of the three-dimensional patterns on the mold surfaces having a maximum relief of at least about 0.5 inches; providing a plurality of molds each having a plurality of side walls defining a mold cavity, each of the molds including one of the plurality of different mold surfaces with the mirror image of the desired three-dimensional patterned concrete block face; introducing dry cast concrete into each of the mold cavities; compacting the dry cast concrete in each of the mold cavities to form a plurality of pre-cured concrete blocks, wherein during compaction, the different desired three-dimensional patterned faces are imparted to the pre-cured concrete blocks by the mold surfaces with the mirror image of the plurality of different desired three dimensional patterned concrete block faces; discharging each of the pre-cured concrete blocks from the respective mold cavity; and curing each of the pre-cured concrete blocks. 2. The method of claim 1 wherein the step of using the digital data set for each of the different three-dimensional patterns to create a plurality of different mold surfaces comprises machining the different mold surfaces. 3. The method of claim 1 wherein the step of compacting the dry cast concrete includes pressing the different desired three-dimensional patterned faces of the mold surfaces into the dry cast concrete contained in the mold cavities. 4. The method of claim 1, including for each of the different three-dimensional patterns the step of displaying a digital image of the selected three-dimensional pattern created from the scanned data prior to the step of using the digital data set to create the mold surface. 5. The method of claim 4, including manipulating the displayed image to modify the three-dimensional pattern, and creating the digital data set from the manipulated image. 6. The method of claim 1, wherein the maximum relief is at least about 1.0 inch. 7. The method of claim 1, wherein the step of selecting includes selecting a plurality of three-dimensional patterns from a plurality of stones. 8. The method of claim 1, wherein each mold surface created by the different digital data sets is a different face of a stripper shoe. 9. The method of claim 7, wherein each mold surface created by the different digital data sets is a different face of a stripper shoe. 10. The method of claim 9, comprising forming a flange along at least a portion of the perimeter of the stripper shoe face. 11. The method of claim 1, wherein the mold surface is metal. 12. The method of claim 1, wherein the step of providing a plurality of molds includes providing a plurality of multiple-cavity molds, each of the multiple-cavity molds including a stripper shoe having the mirror image of the desired three-dimensional patterned concrete block face. 13. The method of claim 1, wherein the step of selecting includes selecting a plurality of patterns simulating multiple pieces of stone stacked in layers. 14. The method of claim 1 wherein the step of compacting the dry cast concrete in each of the mold cavities to form a plurality of pre-cured concrete blocks includes forming a plurality of concrete blocks having a variety of different block front face appearances. 15. A method of making a plurality of concrete blocks having different three dimensional patterned front faces, comprising the steps of: selecting a plurality of different three-dimensional patterns of one or more existing objects; digitally scanning the different selected three-dimensional patterns to create different scanned data in XYZ coordinates that is representative of each of the different selected three-dimensional patterns; creating from each of the different scanned data in the XYZ coordinates a different digital data set for each of the different three-dimensional patterns, the digital data sets being representative of the plurality of different desired three dimensional patterned front faces of the concrete blocks based on the scanned data of the different three-dimensional patterns; using the digital data set for each of the different three-dimensional patterns to create a plurality of different mold shoe faces each having a three-dimensional pattern that is the mirror image of one of the plurality of different desired three dimensional patterned concrete block faces, each of the three-dimensional patterns on the mold shoe faces having a maximum relief of at least about 0.5 inches; providing a plurality of molds each having a plurality of side walls defining a mold cavity, each of the molds including one of the plurality of different mold shoe faces with the mirror-image of the desired three-dimensional patterned concrete block face; positioning a pallet underneath the mold cavities; introducing dry cast concrete into each of the mold cavities; compacting the dry cast concrete in each of the mold cavities to form a plurality of pre-cured concrete blocks with the rear face of the block resting on the pallet and the front face of the block facing upward, the compacting step including introducing the mold shoes into the mold cavities and pressing the faces of the mold shoes having the mirror image of the desired three-dimensional patterned concrete unit faces into the dry cast concrete contained in the mold cavities to impart the desired three dimensional patterned concrete block faces to the front faces of the pre-cured concrete blocks; discharging the pre-cured concrete blocks from the mold cavities; and curing the pre-cured concrete blocks. 16. The method of claim 15 wherein the step of using the digital data set for each of the different three-dimensional patterns to create a plurality of different mold shoe faces comprises machining the mold shoe faces. 17. The method of claim 15, including for each of the three dimensional patterns the step of displaying a digital image of the selected three-dimensional pattern created from the scanned data prior to the step of using the digital data set to create the mold shoe face. 18. The method of claim 17, including manipulating the displayed image to modify the three-dimensional pattern, and creating the digital data set from the manipulated image. 19. The method of claim 15 wherein the maximum relief is at least about 1.0 inch. 20. The method of claim 15, comprising selecting a plurality of three-dimensional patterns from a plurality of stones. 21. The method of claim 15, comprising forming a flange along at least a portion of the perimeter of the mold shoe face. 22. The method of claim 15, wherein the mold shoe is metal. 23. The method of claim 15, wherein the step of providing a plurality of molds includes providing a plurality of multiple-cavity molds, each of the multiple-cavity molds including a stripper shoe having the mirror image of the desired three-dimensional patterned concrete block face. 24. The method of claim 15, wherein the step of selecting includes selecting a plurality of patterns simulating multiple pieces of stone stacked in layers. 25. The method of claim 15 wherein the step of compacting the dry cast concrete in each of the mold cavities to form a plurality of pre-cured concrete blocks includes forming a plurality of concrete blocks having a variety of different block front face appearances.
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이 특허에 인용된 특허 (57)
Ruckstuhl Willi (Augwilerstrasse 48 CH 8302 Kloten CHX), Apparatus for fabrication of concrete brick.
Metten Josef (Mutzerstr. 21 5060 Bergisch Gladbach 2 DEX) Metten Hans-Josef (Mutzerstr. 21 5060 Bergisch Gladbach 2 DEX), Process for the production and treatment of concrete blocks.
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