MODULAR MOLD SETS AND METHODS FOR MANUFACTURING CONSTRUCTION BLOCKS
A mold set for manufacturing interlocking construction blocks comprising a modular family molds and connecting side walls. The molds may be configured to create assembled female molds that may be filled with fluid cement, which can be removed from the female molds with corresponding male molds. Each assembled female mold may comprise one or more interlocking sections that allow the resulting blocks to interlock in three directions along three axes, including a left/right axis, a front/back axis, and an up/down axis. Each block comprises a specific geometry that allows all blocks in the family to interlock in a woven pattern that not only locks the blocks in place but also allows even distribution of structural weights. The disclosed modular mold sets allow blocks to be manufactured in different sizes to conform to any building code requirement and to create wall lengths to a one-inch measurement.
1 . A modular set of interlocking construction block molds, the set comprising:
a female mold, the female mold comprising:
at least one first mold component, the first mold component comprising:
at least one flat wall;
at least one geometric recess; and
at least one aperture defined through the mold;
at least one second mold component, the second mold component comprising:
at least one geometric protrusion; and
at least one aperture defined through the mold;
a plurality of connecting side walls comprising geometrically positioned apertures; and
a plurality of connectors, wherein the plurality of connectors are operable to be received through the geometrically positioned apertures of the plurality of connecting side walls and/or into the first and second mold components, thereby creating a central cavity within the female mold; and
a male mold, the male mold comprising:
a flat top surface; and
at least one vertical pillar extending downwardly from the flat top surface, each vertical pillar ending at least one plunger opposite the flat top surface;
wherein the at least one plunger is sized and shaped to correspond to the size and shape of the central cavity created by the female mold.
2 . The mold set of claim 1 , wherein the geometric recess of the at least one first mold component and the geometric protrusion of the at least one second mold component create a repeating interlocking section geometry when the first mold component is mated with the second mold component.
3 . The mold set of claim 2 , wherein when the first mold component is mated with the second mold component, at least one of the apertures defined through the first mold component align with at least one of the apertures defined through the second mold component.
4 . The mold set of claim 1 , wherein the female mold comprises the same number of first mold components as second mold components.
5 . The mold set of claim 1 , wherein the female mold comprises a different number of first mold components as second mold components.
6 . The mold set of claim 1 , wherein the plurality of connectors are threaded bolts.
7 . The mold set of claim 6 , wherein the connectors further comprise washers.
8 . The mold set of claim 1 , wherein the female mold further comprises a third mold component operable to be received within the central cavity, thereby reducing the volume of the central cavity within the female mold.
9 . The mold set of claim 8 , wherein the third mold component is sized and shaped to create a repeating geometric pattern with the repeating interlocking section geometry of the first mold component and the second mold component.
10 . The mold set of claim 8 , wherein the third mold component comprises two geometric protrusions and is a repeating interlocking mold component.
11 . The mold set of claim 8 , wherein the third mold component comprises a plurality of tabs extending outwardly, the plurality of tabs operable to be received within corresponding notches in the first or second mold components or connecting side walls.
12 . The mold set of claim 11 , wherein the at least one plunger of the male mold is sized and shaped to correspond to the size and shape of the central cavity created by the female mold, the third mold component, and the plurality of tabs.
13 . The mold set of claim 1 , wherein the components of the female mold and the male mold are manufactured from stainless steel.
14 . The mold set of claim 1 , further comprising an internal mesh cage inserted into the central cavity of the female mold, wherein the internal mesh cage is operable to structurally reinforce a block constructed with the mold set.
15 . The mold set of claim 14 , wherein the internal mesh cage is constructed from steel.
16 . The mold set of claim 1 , wherein the central cavity is operable to receive a cement mixture, aggregate, sand, water, or other raw materials used in forming interlocking construction blocks.
17 . A female mold of a modular set of interlocking construction block molds, the female mold comprising:
at least one first mold component, the first mold component comprising:
at least one flat wall;
at least one geometric recess; and
at least one aperture defined through the mold;
at least one second mold component, the second mold component comprising:
at least one flat wall;
at least one geometric protrusion; and
at least one aperture defined through the mold;
a plurality of connecting side walls comprising geometrically positioned apertures; and
a plurality of connectors, wherein the plurality of connectors are operable to be received through the geometrically positioned apertures of the plurality of connecting side walls and into the first and second mold components, thereby creating a central cavity within the female mold.
18 . The female mold of claim 17 , wherein the mold is constructed from stainless steel able to withstand high pressures and temperatures.
19 . A male mold of a modular set of interlocking construction block molds, the male mold comprising:
a flat top surface;
at least one vertical pillar extending downwardly from the flat top surface; and
at least one plunger received on the end of the at least one vertical pillar and opposite the flat top surface;
wherein the at least one plunger is sized and shaped to correspond to the size and shape of the central cavity created by a corresponding female mold.
20 . The male mold of claim 19 , wherein the mold is constructed from stainless steel able to withstand high pressures and temperatures.