MOLD BOX AND METHOD OF MANUFACTURING A BLOCK
The present invention relates a mold box method of manufacturing a block, and a wall block with a stepped-back strata and ledges imprinted on one or more faces of the block. A mold box is provided with a block face liner that is machine cut to create a particular strata and ledge pattern that is widest at the top of the liner and steps back over a plurality of planes to a narrower width at the bottom of the liner. Masonry material is allowed to form in the mold box around the liner to produce the strata and ledges imprint onto one or more faces of the block. The invention also relates to the mold box, multiple embodiments of the block face liner with differing strata and ledge patterns, and to blocks formed in the mold box and methods of constructing walls with the blocks.
1 . A wall block mold comprising first and second opposing side forming surfaces and first and second opposing face forming surfaces, the first and second side forming surfaces and first and second face forming surfaces being positioned to form a perimeter of a mold cavity in the shape of a wall block, at least one of the face forming surfaces having a stepped surface contour which steps outwardly from a top of the mold cavity to a bottom of the mold cavity, the stepped surface contour defining a plurality of planar surfaces, each planar surface having a non-linear edge, each non-linear edge of a planar surface being joined to a non-linear edge of an adjacent planar surface by a ledge, each planar surface being angled outwardly from vertical in the direction of the bottom of the mold cavity by an angle α which is greater than 0°.
2 . The wall block mold of claim 1 further comprising a frame including first and second opposing side walls and first and second opposing end walls and wherein the at least one face forming surface having a stepped surface contour comprises a face forming liner attached to one of the side walls.
3 . The wall block mold of claim 2 wherein the face forming liner has a thickness at the top of the mold cavity which is greater than a thickness at the bottom of the mold cavity to thereby provide the outwardly stepped contour.
4 . The wall block mold of claim 1 wherein both the first and second face forming surfaces have a stepped surface contour.
5 . The wall block mold of claim 1 wherein angle α is in the range of about 1° to 10°.
6 . The wall block mold of claim 1 wherein each ledge comprises a ledge surface that is angled downwardly from horizontal in a direction away from the mold cavity at an angle β which is greater than 0°.
7 . The wall block mold of claim 6 wherein angle β is in the range of about 1° to 10°.
8 . The wall block mold of claim 7 wherein angle β is about 4°.
9 . The wall block mold of claim 1 wherein the plurality of planar surfaces are substantially parallel.
10 . The wall block mold of claim 1 further comprising a plate which forms the bottom surface of the mold cavity.
11 . A method of making a wall block comprising:
providing a mold having first and second opposing side forming surfaces and first and second opposing face forming surfaces, the first and second side forming surfaces and first and second face forming surfaces being positioned to form a perimeter of a mold cavity in the shape of a wall block, at least one of the face forming surfaces having a stepped surface contour which steps outwardly from a top of the mold cavity to a bottom of the mold cavity, the stepped surface contour defining a plurality of planar surfaces, each planar surface having a non-linear edge, each non-linear edge of a planar surface being joined to a non-linear edge of an adjacent planar surface by a ledge, each planar surface being angled outwardly from vertical in the direction of the bottom of the mold cavity by an angle α which is greater than 0°, the mold further having a plate forming a bottom of the mold cavity;
filling the mold cavity with a moldable material; and
removing the moldable material from the bottom of the mold cavity with the moldable material resting on the plate.
12 . The method of claim 11 wherein the mold has a frame including first and second opposing side walls and first and second opposing end walls and wherein the at least one face forming surface having a stepped surface contour comprises a face forming liner attached to one of the side walls.
13 . The method of claim 12 wherein the face forming liner has a thickness at the top of the mold cavity which is greater than a thickness at the bottom of the mold cavity to thereby provide the outwardly stepped contour.
14 . The method of claim 11 wherein both the first and second face forming surfaces have a stepped surface contour.
15 . The method of claim 11 wherein angle α is in the range of about 1° to 10°.
16 . The method of claim 11 wherein each ledge comprises a ledge surface that is angled downwardly from horizontal in a direction away from the mold cavity at an angle β which is greater than 0°.
17 . The method of claim 16 wherein angle β is in the range of about 1° to 10°.
18 . The method of claim 17 wherein angle β is about 4°.
19 . The method of claim 11 wherein the plurality of planar surfaces are substantially parallel.
20 . A wall block comprising first and second opposing side surfaces, first and second opposing face surfaces, and opposing upper and lower surfaces, the side surfaces, face surfaces and upper and lower surfaces together defining a block body, at least one of the face surfaces having a stepped surface contour which steps inwardly from one of the upper surface and lower surface of the block to the other of the upper surface and lower surface of the block, the stepped surface contour defining a plurality of planar surfaces, each planar surface having a non-linear edge, each non-linear edge of a planar surface being joined to a non-linear edge of an adjacent planar surface by a ledge, each planar surface being angled inwardly from vertical by an angle α which is greater than 0°.
21 . The wall block of claim 20 wherein the at least one face surface having a stepped surface contour steps inwardly from the upper surface of the block to the lower surface of the block.
22 . The wall block of claim 20 wherein both the first and second face surfaces have a stepped surface contour.
23 . The wall block of claim 22 wherein the first and second face surfaces are stepped inwardly from the upper surface of the block to the lower surface of the block.
24 . The wall block of claim 20 wherein angle α is in the range of about 1° to 10°.
25 . The wall block of claim 20 wherein each ledge comprises a ledge surface that is angled downwardly from horizontal at an angle β which is greater than 0°.
26 . The wall block of claim 25 wherein angle β is in the range of about 1° to 10°.
27 . The wall block of claim 26 wherein angle β is about 4°.
28 . The wall block of claim 20 wherein the plurality of planar surfaces are substantially parallel.