IP Library › Granted Patent US 9,943,983

Granted Patent B2

US 9,943,983 · App. 15/264,895 · Granted Apr 17, 2018

Block splitter assembly and method of producing wall blocks

Inventors: David M. LaCroix (Eagan, MN); Kyle Bakner (Hedgeville, WV)

Assignee: KEYSTONE RETAINING WALL SYSTEMS LLC

B28D1/222 B28D1/22 B28D1/26

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Quick Facts

Patent No.: US 9,943,983
App. No.: 15/264,895
Granted: Apr 17, 2018
Kind: B2

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Abstract

The invention provides a block splitter device comprising first lower and second upper opposed block splitter assemblies. The block splitter assemblies have first and second forming edges that extend at least the majority of the distance from a first end to a second end of the block splitter assembly and have first ends disposed near a median split plane and second ends disposed further away from the median split plane than the first ends. Methods of using the block splitter device are described.

Claims (38)

1. A block splitter device comprising first lower and second upper opposed block splitter assemblies,

the first block splitter assembly comprising a first end opposed from a second end, a first side surface opposed from a second side surface, a top surface, and a bottom surface, the top surface comprising: (i) a first forming edge extending at least the majority of the distance from the first end to the second end of the first block splitter assembly, the first forming edge having a first end and a second end, the first end of the first forming edge being disposed closer to the first end of the first block splitter assembly than the second end of the first block splitter assembly and being disposed near a median split plane, the median split plane being a reference plane that divides the top surface and the bottom surface of the first block splitter assembly in half and intersects a midpoint between the first and second side surfaces of the first end of the first block splitter assembly and intersects a midpoint between the first and second side surfaces of the second end of the first block splitter assembly, the second end of the first forming edge being disposed closer to the second end of the first block splitter assembly than the first end of the first block splitter assembly and being disposed further away from the median split plane than the first end of the first forming edge, and (ii) a second forming edge extending at least the majority of the distance from the first end to the second end of the first block splitter assembly, the second forming edge having a first end and a second end, the first end of the second forming edge being disposed closer to the second end of the first block splitter assembly than the first end of the first block splitter assembly and being disposed near the median split plane, the second end of the second forming edge being disposed closer to the first end of the first block splitter assembly than the second end of the first block splitter assembly and being disposed further away from the median split plane than the first end of the second forming edge, and

the second block splitter assembly comprising a first end opposed from a second end, a first side surface opposed from a second side surface, a top surface, and a bottom surface, the bottom surface comprising: (i) a first forming edge extending at least the majority of the distance from the first end to the second end of the second block splitter assembly, the first forming edge having a first end and a second end, the first end of the first forming edge being disposed closer to the first end of the second block splitter assembly than the second end of the second block splitter assembly and being disposed near a median split plane, the median split plane being a reference plane that divides the top surface and the bottom surface of the second block splitter assembly in half and intersects a midpoint between the first and second side surfaces of the first end of the second block splitter assembly and intersects a midpoint between the first and second side surfaces of the second end of the second block splitter assembly, the second end of the first forming edge being disposed closer to the second end of the second block splitter assembly than the first end of the second block splitter assembly and being disposed further away from the median split plane than the first end of the first forming edge, and (ii) a second forming edge extending at least the majority of the distance from the first end to the second end of the second block splitter assembly, the second forming edge having a first end and a second end, the first end of the second forming edge being disposed closer to the second end of the second block splitter assembly than the first end of the second block splitter assembly and being disposed near the median split plane, the second end of the second forming edge being disposed closer to the first end of the second block splitter assembly than the second end of the second block splitter assembly and being disposed further away from the median split plane than the first end of the second forming edge.

2. The block splitter of claim 1 , wherein in the first block splitter assembly minimum distances between the first forming edge and the median split plane increase or remain constant over the entire length of the first forming edge from the first end to the second end of the first forming edge and minimum distances between the second forming edge and the median split plane increase or remain constant over the entire length of the second forming edge from the first end to the second end of the second forming edge, and in the second block splitter assembly minimum distances between the first forming edge and the median split plane increase or remain constant over the entire length of the first forming edge from the first end to the second end of the first forming edge and minimum distances between the second forming edge and the median split plane increase or remain constant over the entire length of the second forming edge from the first end to the second end of the second forming edge.

3. The block splitter of claim 1 , wherein the first and second forming edges of the first block splitter assembly do not intersect and the first and second forming edges of the second block splitter assembly do not intersect.

4. The block splitter device of claim 1 , wherein the first and second forming edges of the first block splitter assembly extend the entire distance from the first end to the second end of the first block splitter assembly and the first and second forming edges of the second block splitter assembly extend the entire distance from the first end to the second end of the second block splitter assembly.

5. The block splitter device of claim 1 , wherein the first and second forming edges of the first block splitter assembly and the first and second forming edges of the second block splitter assembly are not opposed to each other.

6. The block splitter device of claim 1 , wherein the first forming edge of the first block splitter assembly has a vertical dimension at its first end and a vertical dimension at its second end, and the vertical dimension of the first forming edge at its first end is greater than the vertical dimension at its second end, the second forming edge of the first block splitter assembly has a vertical dimension at its first end and a vertical dimension at its second end, and the vertical dimension of the second forming edge at its first end is greater than the vertical dimension at its second end, the first forming edge of the second block splitter assembly has a vertical dimension at its first end and a vertical dimension at its second end, and the vertical dimension of the first forming edge at its first end is greater than the vertical dimension at its second end, and the second forming edge of the second block splitter assembly has a vertical dimension at its first end and a vertical dimension at its second end, and the vertical dimension of the second forming edge at its first end is greater than the vertical dimension at its second end.

7. The block splitter device of claim 6 , wherein the first forming edge of the first block splitter assembly has a vertical dimension at the midpoint between the first and second ends of the first block splitter assembly, and the vertical dimension of the first forming edge at its midpoint is greater than the vertical dimension at its second end, the second forming edge of the first block splitter assembly has a vertical dimension at the midpoint between the first and second ends of the first block splitter assembly, and the vertical dimension of the second forming edge at its midpoint is greater than the vertical dimension at its second end, the first forming edge of the second block splitter assembly has a vertical dimension at the midpoint between the first and second ends of the second block splitter assembly, and the vertical dimension of the first forming edge at its midpoint is greater than the vertical dimension at its second end, and the second forming edge of the second block splitter assembly has a vertical dimension at the midpoint between the first and second ends of the second block splitter assembly, and the vertical dimension of the second forming edge at its midpoint is greater than the vertical dimension at its second end.

8. The block splitter device of claim 1 , wherein the first forming edge of the first block splitter assembly extends in an arc for at least a portion of a length from the first end to the second end of the first forming edge, the second forming edge of the first block splitter assembly extends in an arc for at least a portion of a length from the first end to the second end of the first forming edge, the first forming edge of the second block splitter assembly extends in an arc for at least a portion of a length from the first end to the second end of the first forming edge, and the second forming edge of the second block splitter assembly extends in an arc for at least a portion of a length from the first end to the second end of the first forming edge.

9. The block splitter device of claim 1 , wherein the top surface of the first block splitter assembly further comprises a third forming edge having a length and extending at least the majority of the distance from the first end to the second end of the first block splitter assembly, the third forming edge having a first end and a second end, the first end of the third forming edge being disposed closer to the first end of the first block splitter assembly than the second end of the first block splitter assembly, the second end of the third forming edge being disposed closer to the second end of the first block splitter assembly than the first end of the first block splitter assembly and being disposed closer to the median split plane than the first end of the third forming edge, the third forming edge being disposed further away from the median split plane than the first forming edge for at least a majority of the length of the third forming edge and the third forming edge being disposed further away from second forming edge than the first forming edge for at least a majority of the length of the third forming edge, and

the top surface of the first block splitter assembly further comprises a fourth forming edge having a length and extending at least the majority of the distance from the first end to the second end of the first block splitter assembly, the fourth forming edge having a first end and a second end, the first end of the fourth forming edge being disposed closer to the second end of the first block splitter assembly than the first end of the first block splitter assembly, the second end of the fourth forming edge being disposed closer to the first end of the first block splitter assembly than the second end of the first block splitter assembly and being disposed closer to the median split plane than the first end of the fourth forming edge, the fourth forming edge being disposed further away from the median split plane than the second forming edge for at least a majority of the length of the fourth forming edge and the fourth forming edge being disposed further away from the first forming edge than the second forming edge for at least a majority of the length of the fourth forming edge and the fourth forming edge being disposed further away from the third forming edge than from both the first and second forming edges for at least a majority of the length of the fourth forming edge, and

the bottom surface of the second block splitter assembly further comprises a third forming edge having a length and extending at least the majority of the distance from the first end to the second end of the second block splitter assembly, the third forming edge having a first end and a second end, the first end of the third forming edge being disposed closer to the first end of the second block splitter assembly than the second end of the second block splitter assembly, the second end of the third forming edge being disposed closer to the second end of the second block splitter assembly than the first end of the second block splitter assembly and being disposed closer to the median split plane than the first end of the third forming edge, the third forming edge being disposed further away from the median split plane than the first forming edge for at least a majority of the length of the third forming edge and the third forming edge being disposed further away from second forming edge than the first forming edge for at least a majority of the length of the third forming edge, and

the bottom surface of the second block splitter assembly further comprises a fourth forming edge having a length and extending at least the majority of the distance from the first end to the second end of the second block splitter assembly, the fourth forming edge having a first end and a second end, the first end of the fourth forming edge being disposed closer to the second end of the second block splitter assembly than the first end of the second block splitter assembly, the second end of the fourth forming edge being disposed closer to the first end of the second block splitter assembly than the second end of the second block splitter assembly and being disposed closer to the median split plane than the first end of the fourth forming edge, the fourth forming edge being disposed further away from the median split plane than the second forming edge for at least a majority of the length of the fourth forming edge and the fourth forming edge being disposed further away from the first forming edge than the second forming edge for at least a majority of the length of the fourth forming edge and the fourth forming edge being disposed further away from the third forming edge than from both the first and second forming edges for at least a majority of the length of the fourth forming edge.

10. The block splitter device of claim 9 , wherein the top surface of the first block splitter assembly comprises a first forming surface extending between the third forming edge and the first forming edge and a second forming surface extending between the fourth forming edge and the second forming edge, and the bottom surface of the second block splitter assembly comprises a first forming surface extending between the third forming edge and the first forming edge and a second forming surface extending between the fourth forming edge and the second forming edge.

11. The block splitter device of claim 1 , wherein the first and second splitter blade assemblies are identical.

12. The block splitter device of claim 1 , further comprising first and second side knife assemblies.

13. A method of producing a concrete block comprising:

(i) providing a block splitter assembly comprising first lower and second upper opposed splitter blade assemblies,

(ii) placing a concrete workpiece in the block splitter assembly at a splitting position to be engaged by the first and second splitter blade assemblies; and

(iii) with the workpiece at the splitting position, activating the first and second splitter blade assemblies to engage the workpiece and thereby split and form the workpiece.

14. The method of claim 13 , wherein in the first block splitter assembly minimum distances between the first forming edge and the median split plane increase or remain constant over the entire length of the first forming edge from the first end to the second end of the first forming edge and minimum distances between the second forming edge and the median split plane increase or remain constant over the entire length of the second forming edge from the first end to the second end of the second forming edge, and in the second block splitter assembly minimum distances between the first forming edge and the median split plane increase or remain constant over the entire length of the first forming edge from the first end to the second end of the first forming edge and minimum distances between the second forming edge and the median split plane increase or remain constant over the entire length of the second forming edge from the first end to the second end of the second forming edge.

15. The method of claim 13 , wherein the first and second forming edges of the first block splitter assembly do not intersect and the first and second forming edges of the second block splitter assembly do not intersect.

16. The method of claim 13 , wherein the first and second forming edges of the first block splitter assembly extend the entire distance from the first end to the second end of the first block splitter assembly and the first and second forming edges of the second block splitter assembly extend the entire distance from the first end to the second end of the second block splitter assembly.

17. The method of claim 13 , wherein the first and second forming edges of the first block splitter assembly and the first and second forming edges of the second block splitter assembly are not opposed to each other.

18. The method of claim 13 , wherein the first forming edge of the first block splitter assembly has a vertical dimension at its first end and a vertical dimension at its second end, and the vertical dimension of the first forming edge at its first end is greater than the vertical dimension at its second end, the second forming edge of the first block splitter assembly has a vertical dimension at its first end and a vertical dimension at its second end, and the vertical dimension of the second forming edge at its first end is greater than the vertical dimension at its second end, the first forming edge of the second block splitter assembly has a vertical dimension at its first end and a vertical dimension at its second end, and the vertical dimension of the first forming edge at its first end is greater than the vertical dimension at its second end, and the second forming edge of the second block splitter assembly has a vertical dimension at its first end and a vertical dimension at its second end, and the vertical dimension of the second forming edge at its first end is greater than the vertical dimension at its second end.

19. The method of claim 18 , wherein the first forming edge of the first block splitter assembly has a vertical dimension at the midpoint between the first and second ends of the first block splitter assembly, and the vertical dimension of the first forming edge at its midpoint is greater than the vertical dimension at its second end, the second forming edge of the first block splitter assembly has a vertical dimension at the midpoint between the first and second ends of the first block splitter assembly, and the vertical dimension of the second forming edge at its midpoint is greater than the vertical dimension at its second end, the first forming edge of the second block splitter assembly has a vertical dimension at the midpoint between the first and second ends of the second block splitter assembly, and the vertical dimension of the first forming edge at its midpoint is greater than the vertical dimension at its second end, and the second forming edge of the second block splitter assembly has a vertical dimension at the midpoint between the first and second ends of the second block splitter assembly, and the vertical dimension of the second forming edge at its midpoint is greater than the vertical dimension at its second end.

20. The method of claim 13 , wherein the first forming edge of the first block splitter assembly extends in an arc for at least a portion of a length from the first end to the second end of the first forming edge, the second forming edge of the first block splitter assembly extends in an arc for at least a portion of a length from the first end to the second end of the first forming edge, the first forming edge of the second block splitter assembly extends in an arc for at least a portion of a length from the first end to the second end of the first forming edge, and the second forming edge of the second block splitter assembly extends in an arc for at least a portion of a length from the first end to the second end of the first forming edge.

21. The method of claim 13 , wherein the top surface of the first block splitter assembly further comprises a third forming edge having a length and extending at least the majority of the distance from the first end to the second end of the first block splitter assembly, the third forming edge having a first end and a second end, the first end of the third forming edge being disposed closer to the first end of the first block splitter assembly than the second end of the first block splitter assembly, the second end of the third forming edge being disposed closer to the second end of the first block splitter assembly than the first end of the first block splitter assembly and being disposed closer to the median split plane than the first end of the third forming edge, the third forming edge being disposed further away from the median split plane than the first forming edge for at least a majority of the length of the third forming edge and the third forming edge being disposed further away from second forming edge than the first forming edge for at least a majority of the length of the third forming edge, and

22. The method of claim 21 , wherein the top surface of the first block splitter assembly comprises a forming surface extending between the third forming edge and the first forming edge and a forming surface extending between the fourth forming edge and the second forming edge, and the bottom surface of the second block splitter assembly comprises a forming surface extending between the third forming edge and the first forming edge and a forming surface extending between the fourth forming edge and the second forming edge.

23. The method of claim 13 , wherein the first and second splitter blade assemblies are identical.

24. The method of claim 13 , wherein the block produced by the method has a face and the face has a convex shape.

25. The method of claim 13 , wherein the block splitter assembly further comprises first and second side knife assemblies and the first and second side knife assemblies engage the workpiece at the same time that the first and second side knife assemblies engage the workpiece.

Assignments (6)

PATENT SECURITY AGREEMENT (ABL) Recorded Mar 23, 2022

From: UNITED STATES PIPE AND FOUNDRY COMPANY, LLC; GRIFFIN PIPE PRODUCTS CO., LLC; CUSTOM FAB, INC.; BIO CLEAN ENVIRONMENTAL SERVICES, INC.; MODULAR WETLAND SYSTEMS, INC.; FORTERRA PIPE & PRECAST, LLC; FORTERRA CONCRETE PRODUCTS, INC.; FORTERRA PRECAST CONCEPTS, LLC; BEST BLOCK, LLC; PAVESTONE, LLC; CONTECH ENGINEERED SOLUTIONS LLC; KEYSTONE RETAINING WALL SYSTEMS LLC

To: WELLS FARGO BANK, NATIONAL ASSOCIATION, AS AGENT

Reel/Frame 059479/0336 →

PATENT SECURITY AGREEMENT (ABL) Recorded Mar 23, 2022

To: WELLS FARGO BANK, NATIONAL ASSOCIATION, AS AGENT

Reel/Frame 059479/0437 →

SECURITY INTEREST Recorded Mar 18, 2022

From: KEYSTONE RETAINING WALL SYSTEMS LLC

To: WELLS FARGO BANK, N.A., AS AGENT

Reel/Frame 059437/0933 →

ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 20, 2016

From: BAKNER, KYLE

To: RAMPF MOLDS INDUSTRIES INC.