Method for making and treating wall blocks

Abstract

An apparatus and a method for treating the surfaces and edges of a block to mimic the appearance of natural stone. The apparatus and method can treat up to four sides of a block, can be adjusted to provide varying degrees of surface and edge treatment, and useful in high volume block production equipment. Blocks are produced having a natural, weathered appearance without the damage, breakage, dust, or expense associated with conventional splitting and tumbling methods.

1 . A method for treating the surface of a block, the block having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the method comprising: 
 positioning the block in a first treatment station including an edge rounding member;    treating the block in the first treatment station to round the upper and lower face edges of at least one of the first and second opposed faces of the block;    positioning the block in a second treatment station including a surface roughening member; and    treating the block in the second treatment station to roughen a surface of at least one of the first and second opposed faces.    
     
     
         2 . The method of  claim 1  wherein the edge rounding member comprises hammer elements.  
     
     
         3 . The method of  claim 1  wherein the surface roughening member comprises flailing elements.  
     
     
         4 . The method of  claim 1  wherein the step of treating the block in the first treatment station further comprises immobilizing the block.  
     
     
         5 . The method of  claim 1  wherein the step of treating the block in the second treatment station further comprises moving the block through the second treatment station as the surface is roughened.  
     
     
         6 . The method of  claim 1  further comprising: 
 rotating the block within the first treatment station, and    treating the block to round the upper and lower surface edges of at least one of the first and second side surfaces of the block.    
     
     
         7 . The method of  claim 1  further comprising: 
 rotating the block within the second treatment station, and    treating the block to roughen surface of at least one of the first and second side surfaces.    
     
     
         8 . The method of  claim 1  further comprising: 
 moving the block to a third treatment station including an edge rounding member, and    treating the block in the third treatment station to round the upper and lower surface edges of at least one of the first and second side surfaces of the block.    
     
     
         9 . The method of  claim 8  further comprising: 
 moving the block to a fourth treatment station including a surface roughening member; and    treating the block in the fourth treatment station to roughen the surface of the at least one of the first and second side surfaces.    
     
     
         10 . The method of  claim 2  wherein the hammer elements comprise a segment having a plurality of teeth.  
     
     
         11 . The method of  claim 3  wherein the flailing elements comprise hardened steel elements.  
     
     
         12 . A method for treating the surface of a block, the block having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the method comprising: 
 positioning the block in a first hammer station;    treating the block in the first hammer station to round at least one of the upper and lower face edges of at least one of the first and second opposed faces the block;    positioning the block in a first flail station; and    treating the block in the first flail station to roughen a surface of at least one of the first and second opposed faces.    
     
     
         13 . The method of  claim 12  wherein the step of treating the block in the first hammer station further comprises immobilizing the block in a stationary position.  
     
     
         14 . The method of  claim 12  wherein the step of treating the block in the first flail station further comprises moving the block through the second treatment station as the surface is roughened.  
     
     
         15 . The method of  claim 12  further comprising: 
 rotating the block within the first hammer station, and    treating the block to round the upper and lower surface edges of at least one of the first and second side surfaces of the block.    
     
     
         16 . The method of  claim 12  further comprising: 
 rotating the block within the first flail station, and    treating the block to roughen the surface of at least one of extra space remove the first and second side surfaces.    
     
     
         17 . The method of  claim 12  further comprising: 
 moving the block to a second hammer station, and    treating the block in the second hammer station to round the upper and lower surface edges of at least one of the first and second side surfaces of the block.    
     
     
         18 . The method of  claim 12  further comprising: 
 moving the block to a second flail station including a surface roughening member; and    treating the block in the second flail station to roughen the surface of at least one of the first and second side surfaces.    
     
     
         19 . The method of  claim 12  wherein the first hammer station comprises a segment having a plurality of teeth.  
     
     
         20 . The method of  claim 12  wherein the first flail station comprises flailing elements.  
     
     
         21 . The method of  claim 20  wherein the flailing elements comprise hardened steel.  
     
     
         22 . An apparatus for treating the surface of a block, the block having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the apparatus comprising: 
 a first treatment station having an edge rounding member configured to round the upper and lower face edges of at least one of the first and second opposed faces of the block;    a second treatment station having a surface roughening member configured to roughen a surface of the at least one of the first and second opposed faces; and    a first conveying member for moving the block from the first treatment station to the second treatment station.    
     
     
         23 . The apparatus of  claim 22  further comprising a rotating member configured to rotate the block 90 degrees.  
     
     
         24 . The apparatus of  claim 22  further comprising a clamp to hold the block in the first treatment station.  
     
     
         25 . The apparatus of  claim 22  further comprising a conveying means to move the block through the second treatment station while the surface is being roughened.  
     
     
         26 . The apparatus of  claim 22  further comprising a third treatment station having an edge rounding member configured to round of the upper and lower surface edges of the at least one of the first and second opposed faces of the block.  
     
     
         27 . The apparatus of  claim 26  further comprising a fourth treatment station having a surface roughening member configured to roughen the surface of at least one of the first and second side surfaces.  
     
     
         28 . The apparatus of  claim 24  further comprising a second conveying member for moving the block from the second treatment station to the third treatment station.  
     
     
         29 . The apparatus of  claim 25  further comprising a third conveying member for moving the block from the third treatment station to the fourth treatment station.  
     
     
         30 . The apparatus of  claim 22  wherein the edge rounding member comprises hammer elements.  
     
     
         31 . The apparatus of  claim 22  wherein the surface roughening member comprises flailing elements.  
     
     
         32 . The apparatus of  claim 22  wherein the hammer elements comprise a segment having a plurality of teeth.  
     
     
         33 . The apparatus of  claim 32  wherein the segment having the plurality of teeth is linear.  
     
     
         34 . The apparatus of  claim 32  wherein the segment having the plurality of teeth is arcuate.  
     
     
         35 . The apparatus of  claim 22  wherein the flailing elements comprise hardened steel.  
     
     
         36 . An apparatus for shaping the surface of a block, the block having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the apparatus comprising: 
 means for rounding the upper and lower face edges of at least one of the first and second opposed faces of the block;    means for roughening a surface of at least one of the first and second opposed faces of the block; and    means for moving the block between the rounding means and the roughening means.    
     
     
         37 . The apparatus of  claim 36  further comprising means for rounding the upper and lower surface edges of at least one of the first and second side surfaces of the block.  
     
     
         38 . The apparatus of  claim 36  further comprising means for roughening at least one of the first and second side surfaces of the block.  
     
     
         39 . The apparatus of  claim 36  further comprising means for immobilizing the block.  
     
     
         40 . The apparatus of  claim 36  further comprising means for conveying the block to the means for rounding the block.  
     
     
         41 . An apparatus for treating the surface of a block, the block having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the apparatus comprising: 
 a first treatment station having a hammer element configured to round the upper and lower face edges of at least one of the first and second opposed faces of the block;    a second treatment station having a flailing element configured to roughen a surface of at least one of the first and second opposed faces; and    a pusher for moving the block from the first treatment station to the second treatment station.    
     
     
         42 . The apparatus of  claim 41  further comprising a turntable configured to rotate the block.  
     
     
         43 . The apparatus of  claim 41  further comprising a clamp to hold the block in the first treatment station.  
     
     
         44 . The apparatus of  claim 41  further comprising a conveying means to move the block through the second treatment station as the surface is roughened.  
     
     
         45 . The apparatus of  claim 41  further comprising a third treatment station having a hammer element configured to round the upper and lower surface edges of at least one of the first and second side surfaces of the block.  
     
     
         46 . The apparatus of  claim 45  further comprising a fourth treatment station having a flailing element configured to roughen a surface of at least one of the first and second side surfaces.  
     
     
         47 . A method of making wall blocks, the blocks each having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces to form upper and lower surface edges, the method comprising: 
 forming the blocks in a mold which imparts a roughened surface texture to at least one of the faces of the blocks;    removing the blocks from the mold;    positioning at least one of the blocks in a first treatment station; and    rounding the upper and lower face edges of the at least one face of the at least one block having a roughened surface texture in the first treatment station without tumbling the at least one block together with other blocks in a block tumbler.    
     
     
         48 . The method of  claim 47  further comprising curing the blocks.  
     
     
         49 . The method of  claim 47  further comprising: 
 positioning the at least one block in a second treatment station; and    treating the at least one block to further roughen the at least one face having a roughened surface texture.    
     
     
         50 . The method of  claim 47  wherein the step of rounding comprises striking the upper and lower face edges with hammer elements.  
     
     
         51 . The method of  claim 49  wherein the step of treating the at least one block to further roughen a surface comprises striking the block surface with flailing elements.  
     
     
         52 . The method of  claim 47  wherein the step of treating the at least one block in the first treatment station further comprises immobilizing the at least one block.  
     
     
         53 . The method of  claim 47  wherein the step of treating the at least one block in the second treatment station further comprises moving the at least one block through the second treatment station as the surface is roughened.  
     
     
         54 . The method of  claim 47  further comprising: 
 rotating the at least one block within the first treatment station, and    rounding the upper and lower surface edges of at least one of the first and second side surfaces of the block.    
     
     
         55 . The method of  claim 47  further comprising: 
 rotating the block within the second treatment station, and    treating the block to roughen the surface of at least one of the first and second side surfaces.    
     
     
         56 . A method of making wall blocks, the blocks each having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the method comprising: 
 forming the blocks in a mold which imparts a roughened surface texture to at least one of the faces of the blocks;    removing the blocks from the mold;    positioning at least one of the blocks in a first treatment station including an edge rounding member;    rounding the upper and lower face edges of the at least one face of the at least one block having a roughened surface texture in the first treatment station without tumbling the at least one block together with other blocks in a block tumbler;    positioning the at least one block in a second treatment station including a surface roughening member; and    further roughening the surface of the at least one face having a roughened surface texture in the second treatment station.    
     
     
         57 . The method of  claim 56  further comprising curing the blocks.  
     
     
         58 . The method of  claim 56  wherein the step of rounding comprises striking the upper and lower face edges with hammer elements.  
     
     
         59 . The method of  claim 56  wherein the step of further roughening comprises striking the face having a roughened surface texture with flailing elements.  
     
     
         60 . The method of  claim 56  wherein the step of treating the at least one block in the first treatment station further comprises immobilizing the block.  
     
     
         61 . The method of  claim 56  wherein the step of further roughening the at least one block in the second treatment station further comprises moving the at least one block through the second treatment station as the surface is further roughened.  
     
     
         62 . The method of  claim 56  further comprising: 
 rotating the at least one block within the first treatment station, and    rounding the upper and lower surface edges of at least one of the first and second side surfaces of the at least one block.    
     
     
         63 . The method of  claim 56  further comprising: 
 rotating the block within the second treatment station, and    roughening the surface of at least one of the first and second side surfaces of the at least one block.    
     
     
         64 . A method of making wall blocks, the blocks each having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the method comprising: 
 forming the blocks in a mold;    removing the blocks from the mold;    positioning at least one of the blocks in a first treatment station; and    rounding the upper and lower face edges of at least one of the first and second opposed faces of the at least one block in the first treatment station without tumbling the at least one block together with other blocks in a block tumbler.    
     
     
         65 . The method of  claim 64  further comprising curing the blocks.  
     
     
         66 . The method of  claim 64  further comprising: 
 positioning the at least one block in a second treatment station; and    treating the at least one blocks to roughen a surface of the at least one of the first and second opposed faces.    
     
     
         67 . The method of  claim 64  wherein the step of rounding comprises striking the upper and lower face edges with hammer elements.  
     
     
         68 . The method of  claim 66  wherein the step of treating the at least one block to roughen the surface comprises striking the surface with flailing elements.  
     
     
         69 . The method of  claim 64  wherein the step of rounding the edges of the at least one block in the first treatment station further comprises immobilizing the block.  
     
     
         70 . The method of  claim 66  wherein the step of treating the at least one block in the second treatment station further comprises moving the at least one block through the second treatment station as the surface is roughened.  
     
     
         71 . The method of  claim 64  further comprising: 
 rotating the block within the first treatment station, and    rounding the upper and lower surface edges of at least one of the first and second side surfaces block.    
     
     
         72 . The method of  claim 66  further comprising: 
 rotating the at least one block within the second treatment station, and    treating the at least one block to roughen the surface of at least one of the first and second side surfaces.    
     
     
         73 . A method of making wall blocks, the blocks each having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the method comprising: 
 forming the blocks in a mold;    removing the blocks from the mold;    positioning the blocks in a first treatment station including an edge rounding member;    rounding the upper and lower face edges of at least one of the first and second opposed faces of the blocks in the first treatment station;    positioning the blocks in a second treatment station including a surface roughening member; and    roughening the at least one of the first and second opposed faces in the second treatment station.    
     
     
         74 . The method of  claim 73  further comprising curing the blocks.  
     
     
         75 . The method of  claim 73  wherein the step of rounding comprises striking the block edges with hammer elements.  
     
     
         76 . The method of  claim 73  wherein the step of roughening comprises striking the at least one face with flailing elements.  
     
     
         77 . The method of  claim 73  wherein the step of rounding the upper and lower face edges further comprises immobilizing the blocks.  
     
     
         78 . The method of  claim 73  wherein the step of roughening further comprises moving the blocks through the second treatment station as the at least one face is roughened.  
     
     
         79 . The method of  claim 73  further comprising: 
 rotating the blocks within the first treatment station, and    rounding the upper and lower surface edges of at least one of the first and second side surfaces of the block.    
     
     
         80 . The method of  claim 73  further comprising: 
 rotating the blocks within the second treatment station, and    roughening at least one of the first and second side surfaces in the second treatment station.    
     
     
         81 . A method for treating the surface of a block, the block having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces of the block to form upper and lower surface edges, the method comprising: 
 positioning the block in a first treatment station including an edge rounding member;    treating the block in the first treatment station to round at least one of the upper and lower face edges of at least one of the first and second opposed faces of the block;    positioning the block in a second treatment station including a surface roughening member; and    treating the block in the second treatment station to roughen a surface of at least one of the first and second opposed faces.    
     
     
         82 . A method of making wall blocks, the blocks each having an upper surface opposed to a lower surface, first and second opposed faces joining the upper and lower surfaces of the block to form upper and lower face edges, and first and second side surfaces joining the upper and lower surfaces to form upper and lower surface edges, the method comprising: 
 forming the blocks in a mold which imparts a roughened surface texture to at least one of the faces of the blocks;    removing the blocks from the mold;    positioning at least one of the blocks in a first treatment station; and    rounding at least one of the upper and lower face edges of the at least one face of the at least one block having a roughened surface texture in the first treatment station without tumbling the at least one block together with other blocks in a block tumbler.