Method and mold for manufacturing an interlocking concrete block

Abstract

A mold and method for manufacturing interlocking concrete blocks. The mold comprises a mold box, comprising two side walls joined to end walls to define a mold cavity, a top face, and a substantially open bottom face. Top insert members are configured to define a space between adjacent blocks, for forming a portion of the transverse profile of the top surface of one block or a portion of the transverse profile of the bottom surface of an adjacent block, or both. A removable draw plate for closing the bottom of the mold box comprises a generally planar floor and bottom insert members configured to define a space between adjacent blocks, for forming a remaining portion of the transverse profile of the top surface of one block or a remaining portion of the transverse profile of the bottom surface of an adjacent block, or both.

Claims

1. A mold for manufacturing at least one interlocking concrete block, the at least one block having a top surface having a transverse profile comprising at least one interlocking structure projecting from or recessed into the top surface, and a bottom surface having a transverse profile comprising at least one complementary interlocking structure projecting from or recessed into the bottom surface, the mold comprising: a mold box, comprising: two side walls joined to end walls to define a mold cavity, a top face, and a substantially open bottom face; and top insert members configured to define a space between adjacent blocks or a space between a block and a side of the mold box, extending between the end walls of the box substantially from the top face into the mold cavity, for forming a portion of the transverse profile of the top surface of one block or a portion of the transverse profile of the bottom surface of an adjacent block or both; and a removable draw plate for closing the bottom of the mold box, comprising: a generally planar floor; and bottom insert members configured to define a space between adjacent blocks, or a space between a block and a side of the mold box, extending between the end walls and projecting from the floor into the mold cavity, for forming a remaining portion of the transverse profile of the top surface of one block or a remaining portion of the transverse profile of the bottom surface of an adjacent block, or both; wherein at least one end wall of the mold box provides openings for receiving the bottom insert members, the bottom insert members can be received in and retracted from the openings in the at least one end wall of the mold box both horizontally and vertically, and some of the bottom insert members comprise an undercut surface, the undercut surface being provided with a filler block to close a gap between the end wall and the undercut surface.

2. The mold of claim 1 for manufacturing a plurality of interlocking concrete blocks.

3. The mold of claim 1 wherein the concrete blocks are provided with tongue and groove interlocking structures.

4. The mold of claim 1 comprising openings in both end walls of the mold box, wherein the bottom insert members extend through both end walls when the draw plate is in position in the mold.

5. The mold of claim 1 wherein at least one top insert member is formed integrally with at least one of the side walls.

6. The mold of claim 3 wherein the top insert members extend substantially between the end walls of the mold box, for manufacturing concrete blocks wherein the tongue and groove interlocking structures extend substantially between the ends of the concrete blocks.

7. A system for manufacturing at least one interlocking concrete block in the mold of claim 1 wherein an exposed face of the at least one concrete block is generally flush with the top face of the mold, comprising a press head for imparting a profile or texture, or both, to the exposed face.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In drawings which illustrate an embodiment of the invention by way of example only:

(2) FIGS. 1A to 1L are views showing a typical molding process for a prior art interlocking concrete block.

(3) FIG. 2 is a plan view of a mold according to the invention.

(4) FIG. 3 is a cross-section of the mold taken along the line 3-3 in FIG. 2.

(5) FIG. 4 is a cross-section of the mold taken along the line 4-4 in FIG. 2.

(6) FIG. 5 is a side elevation of the mold of FIG. 2.

(7) FIG. 6 is a perspective view of the draw plate in the mold of FIG. 2 taken from the front-left.

(8) FIG. 7 is a perspective view of the draw plate in the mold of FIG. 2 taken from the front-right.

(9) FIG. 8 is an enlarged partial perspective view of the draw plate in the mold of FIG. 2.

(10) FIG. 9 is a perspective view of the mold box in the mold of FIG. 2 taken from the top-right.

(11) FIG. 10 is a perspective view of the mold box in the mold of FIG. 2 taken from the bottom-left.

(12) FIG. 11 is an exploded perspective view of the mold box in the mold of FIG. 2.

(13) FIGS. 12A to 12H illustrate steps in the manufacture of concrete blocks using the mold of FIG. 2.

(14) FIG. 13 is a perspective view of a retaining wall utilizing interlocking concrete blocks produced by the mold and method of the invention.

DETAILED DESCRIPTION OF THE INVENTION

(15) The present invention provides a mold for and method of manufacturing an interlocking concrete block 20 which has an exposed face to which fully controllable custom textures and profiles can be applied with a press head, in some embodiments without removing the blocks 20 from the mold box. The exposed faces of the blocks 20 can also be coloured as desired, using a minimal amount of expensive concrete pigment in a face coat which can be as little as 10-15 mm thick. The height tolerance of each block 20 is determined by sturdy, fixed structures within the mold itself, rather than by a moving press head as in the prior art technique described above, and is therefore perfect so each block is substantially identical in height with all other blocks cast in the same mold. This is a major benefit for ease of installation compared to prior art systems. By changing the orientation of the blocks 20 within the mold, particularly with the exposed face 28 facing upwardly, the potential for changing the aesthetics of the exposed block face 28 is significantly increased. In order to do this, two main technological advances over the prior art have been employed: 1. The draw plate 14 has historically played a minor role in the formation of the block shape, mainly limited to small or shallow grooves, such as a keyway or a chamfer as shown in FIGS. 1D and 1L. According to the invention, the draw plate becomes an important component in the formation of both the positive and negative structures of the block 20. As such the draw plate should be manufactured with increased robustness, stiffness, and strength, and so as to accommodate the undercut shape as it passes through the end wall of the mold, as described below. The draw plate design provides large, vertical structural elements for this purpose, which have never been used in this type of mold. 2. The invention represents the first concrete block mold to have the mold box and the draw plate combine to form a single structural element of the block 20, such as the upper tongue 22a. In the prior art, the top surface 22 of the block 20 is created with the press head 15, which includes a negative of the entire tongue 22a. The bottom surface 24 of the block 20, which would include minor grooves or chamfers, is created by the draw plate 14. According to the invention, inserts within the mold box and vertical projections from the draw plate meet to form both the upper tongue 22a and the complementary lower groove 24a. The mold box and draw plate combine to form each of the top surface 22 of the block 20 and the bottom surface 24 of the block 20, which has never been done in this type of mold.

(16) The invention accomplishes this by providing, in the preferred embodiment, a mold 30 in which the interlocking concrete blocks are cast in an orientation such that their exposed faces 28 are at the top of the mold 30. The blocks 20 are thus oriented such that the top surface 22 of one block 20 is adjacent to the bottom surface 24 of the block 20 beside it (or the wall 34 of the mold box 32). The mold box 32 for a typical block configuration is thus deeper than a prior art mold box 12, but commensurately smaller side-to-side so the footprint required for the casting process is reduced. Thus, interlocking concrete blocks 20 can be manufactured according to the method of the invention with a higher throughput for the same amount of floor space.

(17) As noted above, providing the exposed faces 28 of the interlocking concrete blocks 20 at the top of the mold 30 also allows for the application of a surface coat of face mix or another suitable, durable coating material to be applied while the blocks 20 are still in the mold 30. The exposed faces 28 may be coloured as desired without having to colour the concrete used for the body of the interlocking concrete block 20, and/or formed to any desired texture or profile.

(18) The invention thus provides a mold for manufacturing at least one interlocking concrete block, the at least one block having a top surface having a transverse profile comprising at least one interlocking structure projecting from or recessed into the top surface, and a bottom surface having a transverse profile comprising at least one complementary interlocking structure projecting from or recessed into the bottom surface, the mold comprising a mold box, comprising two side walls joined to end walls to define a mold cavity, a top face, and a substantially open bottom face, and top insert members configured to define a space between adjacent blocks or a space between a block and a side of the mold box, extending between the end walls of the box substantially from the top face into the mold cavity, for forming a portion of the transverse profile of the top surface of one block or a portion of the transverse profile of the bottom surface of an adjacent block or both, and a removable draw plate for closing the bottom of the mold box, comprising a generally planar floor, and bottom insert members configured to define a space between adjacent blocks, or a space between a block and a side of the mold box, extending between the end walls and projecting from the floor into the mold cavity, for forming a remaining portion of the transverse profile of the top surface of one block or a remaining portion of the transverse profile of the bottom surface of an adjacent block, or both.

(19) The invention further provides a method of manufacturing a plurality of interlocking concrete blocks each having a top surface having a transverse profile comprising at least one interlocking structure projecting from or recessed into the top surface and a bottom surface having a transverse profile comprising at least one complementary interlocking structure projecting from or recessed into the bottom surface, in a mold comprising a mold box comprising two side walls joined to end walls to define a mold cavity, a top face, and a substantially open bottom face, top insert members configured to define a space between adjacent blocks or a space between a block and a side of the mold box extending between the end walls of the box substantially from the top face into the mold cavity for forming an upper portion of the transverse profile of the top surface of one block or an upper portion of the transverse profile of the bottom surface of an adjacent block or both, and a draw plate comprising a generally planar floor and bottom insert members configured to define a space between adjacent blocks or a space between a block and a side of the mold box extending between the end walls and projecting from the floor into a mold cavity, for forming a remaining portion of the transverse profile of the top surface of one block or a remaining portion of the transverse profile of the bottom surface of an adjacent block, or both, comprising the steps of: a. fitting the mold box to the draw plate such that the bottom insert members are received into openings in the end walls of the mold box; b. feeding concrete into the mold cavity; c. consolidating the concrete; d. in any order: i. sliding the draw plate out of the mold in a lateral direction; and ii. removing the formed blocks from the mold box.

(20) FIGS. 2 to 11 illustrate a mold 30 for manufacturing a plurality of interlocking concrete blocks 20 according to the invention. The interlocking blocks 20 are of the type having a top surface 22 with a transverse profile comprising at least one interlocking structure projecting from or recessed into the top surface 22, in the embodiment shown a tongue or rib 22a, and a bottom surface 24 having a transverse profile comprising at least one complementary interlocking structure projecting from or recessed into the bottom surface 24, in the embodiment shown a groove or recess 24a complementary to the tongue 22a.

(21) The projecting rib 22a on the top 22 of the block 20 extends laterally (i.e. in the end-to-end direction), and the recess 24a complementary to the rib 22a also extends laterally, providing a tongue and groove interlock which prevents one block 20 from shifting transversely relative to the block 20 immediately above or beneath in the structure, as best seen in FIG. 5. In the embodiment illustrated the interlocking structures 22a, 24a extend fully between the ends 26 of the block 20, however it will be appreciated that the interlocking structures 22a, 24a may extend partially between the ends 26 of the block 20. The precise length, height, shape and placement of the interlocking structures 22a, 24a is a matter of selection and is in no way limited by the particular embodiment illustrated.

(22) In the preferred embodiment of the invention, the blocks 20 are oriented in the mold 30 such that the exposed face 28 of each block 20, defined herein as the face of the block 20 that is intended to be visible in the finished structure (for example a retaining wall), is disposed in a plane generally parallel to the top face 40 of the mold 30, preferably flush with the top of the mold 30.

(23) The mold 30 comprises a mold box 32, comprising two side walls 34 joined to two end walls 36 to define a mold cavity 38. The bottom face 50 of the mold box 32, best seen in FIG. 10, is substantially open. The top face 40 is open between top insert members 42, 52 and 54. As illustrated in FIG. 11, one end wall 36 of the mold box 32 may be formed separately from the remainder of the mold box 32, which allows the mold box 32 to be manufactured by conventional casting techniques. The detached end 36 may be bolted to the remainder of the mold box 32 or affixed by any other suitable means.

(24) Top insert members 42 are configured to define a space between adjacent blocks 20, and top insert members 52, 54 are configured to define a space between blocks 20 disposed at the sides of the mold 30 and the respective side walls 34. Top insert members 42, 52 and 54 extend between the end walls 36 of the mold box 32, substantially from the top face 40 (i.e. generally flush with the top of the mold box 32) into the mold cavity 38.

(25) The top insert members 42 are configured to form an upper portion of the transverse profile of the top surface 22 of one block 20 and an upper portion of the transverse profile of the bottom surface 24 of an adjacent block 20 in the mold 30. The top insert members 42 are accordingly provided on one side 42a with a profile that is a negative of the transverse profile of a portion of the bottom surface 24 of the block 20; and on the other side 42b with a profile that is a negative of the transverse profile of a portion of the top surface 22 of the block 20. In the embodiment shown, for example, the top insert members 42 are provided on side 42a with a profile complementary to the transverse profile of the portion of the bottom surface 24 of the block 20 extending from the exposed face 28 up to but not including the recess 24a. The other side 42b is provided with a profile complementary to the transverse profile of the portion of the top surface 22 of the block 20 extending from the exposed face 28 up to and including the outermost surface of the rib 22a.

(26) To complete these portions of the transverse profiles of the blocks 20 that are disposed along the sides 34 of the mold box 32, top inserts 52, 54 are provided defining a space between a block 20 and each side of the mold box 32. The insert 52 is configured with the same complementary profile as the side 42a of the insert member 42 and extends between the ends 36 of the mold box 32 along one side 34, and thus forms an upper portion of the transverse profile of the bottom surface 24 of the block 20 disposed along the side of the mold 30 at the left in FIG. 2. The insert 54 is configured with the same complementary profile as the side 42b of the insert member 42 and extends between the ends 36 of the mold box 32 along the other side 34, and thus forms an upper portion of the transverse profile of the top surface 22 of the block 20 disposed along the side of the mold 30 at the right in FIG. 2. Top inserts 52, 54 may be formed integrally with the sides 34 of the mold box 32, as in the embodiment illustrated, or may be affixed to the interior surface of the sides 34 of the mold box 32 in any suitable fashion.

(27) The mold floor is formed by a removable draw plate 60, for closing the bottom face 50 of the mold box 32 and containing the concrete during casting. The draw plate 60 comprises a generally planar floor 62 which spans at least the length and width of the bottom 50 of the mold box 32, to thereby seal the bottom of the mold cavity 38 sufficiently to prevent concrete from seeping out of the mold 30 under the force of gravity and compression/consolidation. Extending between the end walls 36 of the mold box 32 and projecting from the planar floor 62 into the mold cavity 38 (when the draw plate 60 is in position for casting) are bottom insert members 64 and 66. Bottom insert members 64 are configured to define a space between adjacent blocks 20, and between blocks 20 disposed at the sides of the mold 30 and the respective side wall 34, for forming the remaining portion of the transverse profile of the bottom surface 24 of a block 20, in the embodiment shown extending from the rear face 29 of the block 20 up to and including the recess 24a. Bottom insert members 66 are configured to define a space between adjacent blocks for forming the remaining portion of the transverse profile of the top surface 22 of a block 20, in the embodiment shown extending from the rear face 29 of the block 20 up to but not including the rib 22a. Thus, bottom insert members 64 and 66 form the remainder of the transverse profiles of the top and bottom surfaces 22, 24 of the interlocking block 24, as best seen in FIG. 4.

(28) At least one end wall 36 of the mold box 32 provides openings 64a, 66a into which the bottom insert members 64, 66 are respectively received. Preferably the openings 64a, 66a closely match the profiles of the bottom insert members 64, 66, respectively, providing a seal that substantially prevents concrete from seeping out of the openings 64, 66 when the draw plate 60 is in position in the mold 30. It may in some embodiments be advantageous to provide openings 64a, 66a in both end walls 36, as in the embodiment shown (best seen in FIG. 10).

(29) As shown in FIGS. 9 and 10, at the entrance end of the mold box 32 the end wall 36 includes openings 64a, 66a that allow the mold box 32 to sit flush on the draw plate 60 without interference by bottom insert members 64, 66, so that the bottom insert members 64, 66 project into the mold cavity 38 during casting. In the preferred embodiment the mold box 32 should be capable of being lifted up off of and placed down over the draw plate 60 in a vertical direction, to facilitate an automated transition between casting cycles. However, since the bottom insert members 64 of the draw plate 60 include an undercut area 64b, the openings 64a in the end wall 36 of the mold box 32 must be as wide as the widest portion 64c of the bottom insert 64 (which forms the deepest part of the recess 24a in the block 20), so as not interfere with the raising and lowering of the mold box 32 between casting cycles. As a result, a gap is formed in the mold box end wall 36 at the undercut portion 64b of the profile of the bottom insert 64. In order to prevent the seepage of the concrete mix out of the entrance end wall 36 through this gap, the undercut area at the end of the bottom insert 64 that is positioned within the end wall 36 of the mold box 32 is filled, as by filler block 64d, which closes this gap when the draw plate 60 is in position in the mold 30 for casting, as best seen in FIG. 8. The filler block 64d should be formed in such a way that the concrete material does not stick to or accumulate around the filler block 64d, so in the preferred embodiment a radius or fillet-type transition to the filler block 64d is provided.

(30) In the preferred embodiment openings 64a, 66a are provided in both end walls 36 of the mold box 32, as shown in FIG. 10, so that the insert members 64,66 intrude into the thickness of both end walls 36. Thus, in the embodiment illustrated the insert members 64 extend only through the thickness of the rear end wall 36 and no further. A plate 64e or other covering member is affixed to the exterior surface of the rear end wall 36 over the openings 64a, as shown in FIGS. 9 and 10, to contain the concrete (the small concrete protrusion that intrudes into the undercut area 64b of insert member 64 within the end wall thickness can be removed with a chisel or blade). In an alternative arrangement (not shown) the insert members 64 can terminate at the interior surface of the rear end wall 36, in which case no openings 64a would be required in the rear end wall 36, although openings 64a would still be advantageously provided in the front end wall 36 so that after casting the draw plate 60 can be slid horizontally out of the mold 30 while the blocks 20 are still in the mold box 32.

(31) In a still further alternative (not shown), the openings 64a in the end walls 36 can be formed to match the profile of the insert members 64, including the undercut 64a, and the concrete will be retained within the mold cavity 38 because of the close fit of the openings 64a around the insert members 64. However, in this embodiment the draw plate 60 must be inserted horizontally into the mold box 32, rather than the mold box 32 being lowered vertically onto the draw plate 60, which makes automation more complex.

(32) It will be appreciated that the insert members 42, 54, 56, 64 and 66 extend fully between the end walls 36 of the mold box 32 because the ribs 22a and recesses 24a extend fully end-to-end across the blocks 20. In embodiments where the interlocking structures do not extend fully end-to-end across the blocks 20, the insert members 42, 54, 56, 64 and 66 will only have the length necessary to form the interlocking structures.

(33) FIGS. 12A to 12H illustrate the casting cycle using a mold 30 of the invention, preferably in a generally automated process. The draw plate 60 is positioned on a riser or palette (not shown), as shown in FIG. 12A, and the mold box 32 is lowered onto the draw plate 60 by aligning bottom insert members 64, 66 with their respective openings 64a, 66a in the end walls 36 of the mold box 32 until the mold box 32 is seated on the floor 62, such that the draw plate 60 closes the bottom of the mold box 32, as shown in FIG. 12B. Concrete 2 is then fed into the mold 30, as shown in FIG. 12C, through the openings between the top insert members 42, 52 and 54. The press head 15 is activated, as shown in FIG. 12D, to consolidate the concrete and, if desired, impart a texture or profile to the exposed faces 28 of the blocks 20.

(34) The press head 15 is retracted, as shown in FIG. 12E, and in the preferred embodiment the draw plate 60 is removed by drawing the draw plate 60 out of one end 36 of the mold box 32, as shown in FIG. 12F. Because of the uniform transverse profile of the blocks along the lateral extent of each block 20, the draw plate 60 can be removed laterally from the mold box 32 substantially unimpeded by the interlocking structures formed on the concrete blocks 20.

(35) The mold box 32 is then lifted off of the newly formed blocks 20, as shown in FIG. 12G. Because there is no positive interlock between the top insert members 42, 52, or 54, and the upper portions of the transverse profiles of the blocks 20, as can be seen in FIG. 3, the mold box 32 can be lifted off of the concrete blocks 20 without obstruction. The upper portion of the transverse profile of each block 20 formed by the top insert members 42 (and inserts 52, 54) is selected so that no portion of the top 22 or bottom 24 of the block interlocks in a vertical direction with the top insert members 42, 52 or 54.

(36) It is advantageous to slide the draw plate 60 out from under the newly formed blocks 20 while the mold box 32 is still in position. Alternatively, the mold box 32 can be lifted first and the blocks 20 held in position by other means as the draw plate 60 is drawn out from underneath the blocks.

(37) Finally, as shown in FIG. 12H, the newly formed blocks 20 are forced together and stood upright, to be placed on a skid for shipping.

(38) The components of the mold 30 would typically be formed from steel or any other suitable material. The embodiment illustrated is dimensioned to cast three concrete blocks 20, however the mold 30 can be designed to cast fewer or more concrete blocks 20 as desired, the components of the mold 30 being provided with thicknesses suitable for withstanding the weight of the concrete without deforming. It will be appreciated that since the components of the mold box 32 and draw plate 60 combine to form parallel surfaces, increased accuracy of mold construction and manufacturing may be required.

(39) It will be appreciated that although the blocks 20 are illustrated as oriented in the same direction in the mold 30, because of the versatility in providing profiles on the inserts 42, 52, 54, 64, 66, the blocks 20 can be oriented in the mold 30 in different directions, for example some facing rib-to-rib and others oriented rib-to-recess as shown.

(40) A mold and method for manufacturing interlocking concrete blocks has been described. In an embodiment, the mold comprises a mold box, comprising two side walls joined to end walls to define a mold cavity, a top face, and a substantially open bottom face. Top insert members are configured to define a space between adjacent blocks, for forming a portion of the transverse profile of the top surface of one block or a portion of the transverse profile of the bottom surface of an adjacent block, or both. A removable draw plate for closing the bottom of the mold box comprises a generally planar floor and bottom insert members configured to define a space between adjacent blocks, for forming a remaining portion of the transverse profile of the top surface of one block or a remaining portion of the transverse profile of the bottom surface of an adjacent block, or both. Thus, inserts within the mold box and vertical projections from the draw plate combine to form the top and bottom surfaces of the block, making the draw plate a more important component in the formation of both the positive and negative structures of the block.

(41) Various embodiments of the present invention having been thus described in detail by way of example, it will be apparent to those skilled in the art that variations and modifications may be made without departing from the invention. For example, although less advantageous than the preferred embodiments, the blocks 20 could be formed in the mold with their exposed faces 28 at the bottom of the mold while still providing some advantages of the invention. The invention includes all such variations and modifications as fall within the scope of the appended claims.