MOLD BOX AND METHOD OF MANUFACTURING MULTIPLE BLOCKS
A mold box with an angled division plate and methods for making blocks of various shapes and sizes and columns and walls constructed with the blocks. Multiple embodiments of the mold box are disclosed for enabling different numbers of blocks and sizes of blocks to be formed in a single mold box.
1 . A mold assembly for use in producing wall blocks of different sizes comprising:
a horizontally oriented planar bottom member;
first and second opposing and parallel side walls;
first and second opposing and parallel end walls, the side walls and end walls being joined to form an enclosed perimeter portion, the bottom member enclosing a bottom of the enclosed perimeter portion, a top of the enclosed perimeter portion being open; and
a planar division plate having a first end adjacent the first end wall and a second end adjacent the second end wall, the division plate being oriented in a perpendicular position with respect to the pallet and dividing the enclosed perimeter portion into first and second mold cavities, each mold cavity having opposing cavity end walls formed by the parallel end walls of the enclosed perimeter portion, the division plate being positioned at an angle α with respect to the side walls, angle α being an acute angle greater than 0° such that each of the first and second mold cavities have parallel cavity end walls and non-parallel cavity side walls.
2 . The mold assembly of claim 1 wherein the enclosed perimeter portion is square.
3 . The mold assembly of claim 1 wherein the enclosed perimeter portion is rectangular.
4 . The mold assembly of claim 1 wherein the first and second mold cavities are the same size.
5 . The mold assembly of claim 1 wherein angle α is in the range of about 5° to 10°.
6 . The mold assembly of claim 1 wherein angle α is about 7.125°.
7 . The mold assembly of claim 1 further including at least one mold liner connected to at least one of the side walls, end walls, and division plate.
8 . A method of making blocks of differing size comprising:
placing a mold over a horizontal pallet, the mold including first and second opposing and parallel side walls, and first and second opposing and parallel end walls, the side walls and end walls being joined to form an enclosed perimeter of the mold, the pallet enclosing a bottom of the enclosed perimeter portion, a top of the enclosed perimeter portion being open, the mold further including a planar division plate having a first end adjacent the first end wall and a second end adjacent the second end wall, the division plate being perpendicular to the pallet and dividing the enclosed perimeter portion into first and second mold cavities, each mold cavity having opposing cavity end walls formed by the parallel end walls of the enclosed perimeter portion, the division plate being positioned at an angle α with respect to the side walls, angle α being an acute angle greater than 0° such that each of the first and second mold cavities have parallel cavity end walls and non-parallel cavity side walls;
filling the mold cavities with a moldable material to form a first slab in the first mold cavity and a second slab in the second mold cavity;
applying downward pressure with a stripper head assembly to remove the first and second slabs from the mold;
curing the first and second slabs;
splitting the first slab into first and second blocks; and
splitting the second slab into third and fourth blocks, each of the first, second, third and fourth blocks having opposing and parallel first and second face surfaces and opposing and non-parallel first and second side walls.
9 . The method of claim 8 wherein the enclosed perimeter portion is square.
10 . The method of claim 8 wherein the enclosed perimeter portion is rectangular.
11 . The method of claim 8 wherein the first and second slabs are the same size.
12 . The method of claim 8 wherein angle α is in the range of about 5° to 10°.
13 . The method of claim 8 wherein angle α is about 7.125°.
14 . The method of claim 8 wherein the mold further includes at least one mold liner connected to at least one of the side walls, end walls, and division plate.
15 . The method of claim 8 wherein a distance between the face surfaces of each of the first, second, third and fourth blocks is the same and a distance between the side walls of each of the first, second, third and fourth blocks as measured along the first face surface is different.
16 . The method of claim 8 wherein the moldable material is one of zero slump concrete and wet cast concrete.
17 . A mold assembly for use in producing wall blocks of different sizes comprising:
a horizontally oriented planar bottom member;
first and second opposing and parallel side walls;
first and second opposing and parallel end walls, the side walls and end walls being joined to form an enclosed perimeter portion, the bottom member enclosing a bottom of the enclosed perimeter portion, a top of the enclosed perimeter portion being open; and
at least three planar division plates, each division plate having a first end adjacent the first end wall and a second end adjacent the second end wall, the division plates being oriented in a perpendicular position with respect to the pallet and dividing the enclosed perimeter portion into a plurality of elongate mold cavities, each mold cavity having opposing cavity end walls formed by the parallel end walls of the enclosed perimeter portion, at least two of the at least three division plates being positioned at an angle α with respect to the side walls, angle α being an acute angle greater than 0°, at least one of the at least three division plates being parallel to the side walls and being positioned between the at least two division plates positioned at an angle α such that each of the plurality of mold cavities have parallel cavity end walls and non-parallel cavity side walls.
18 . The mold assembly of claim 17 wherein the enclosed perimeter portion is square.
19 . The mold assembly of claim 17 wherein the enclosed perimeter portion is rectangular.
20 . The mold assembly of claim 17 wherein the plurality of mold cavities are the same size.
21 . The mold assembly of claim 17 wherein angle α is in the range of about 5° to 10°.
22 . The mold assembly of claim 17 wherein angle α is about 7.125°.
23 . The mold assembly of claim 17 further including at least one mold liner connected to at least one of the side walls, end walls, and division plates.