Masonry blocks and masonry block assemblies having molded utility openings

Abstract

A masonry block molded by a masonry block machine employing a mold assembly having a plurality of liner plates, at least one of which is moveable. The masonry block includes a first transverse face, a second transverse face opposing the first transverse face, at least one aperture extending through the masonry block between the first and second transverse faces, a first end face joining the first and second transverse faces, a second end face opposite the first end face and joining the first and second transverse faces, a first major face joining the first end and second end faces, and a second major face opposing the first major face and joining the first and second end faces. A molded utility opening extends through the first major face to the at least one aperture and adapted to receive a utility device, wherein the first major face and molded utility opening are formed during a molding process by action of a moveable liner plate having a mold element which is a negative of the molded utility opening.

1 . A masonry block molded by a masonry block machine employing a mold assembly having a plurality of liner plates, at least one of which is moveable; the masonry block comprising: 
 a first transverse face;    a second transverse face opposing the first transverse face;    at least one aperture extending through the masonry block between the first and second transverse faces;    a first end face joining the first and second transverse faces;    a second end face opposite the first end face and joining the first and second transverse faces;    a first major face joining the first end and second end faces;    a second major face opposing the first major face and joining the first and second end faces; and    a molded utility opening extending through the first major face to the at least one aperture and adapted to receive a utility device, wherein the first major face and molded utility opening are formed during a molding process by action of a moveable liner plate having a mold element which is a negative of the molded utility opening.    
   
   
       2 . The masonry block of  claim 1 , wherein the moveable liner plate is moved with a gear drive assembly.  
   
   
       3 . The masonry block of  claim 1 , wherein the molded utility opening is formed with a desired shape and with desired dimensions.  
   
   
       4 . The masonry block of  claim 1 , including a plurality of molded utility openings extending through the first major face to the at least one aperture, each molded utility opening adapted to receive a corresponding utility device and each formed by action of the moveable liner plate.  
   
   
       5 . The masonry block of  claim 1 , wherein the molded utility opening is formed with a desired shape and with desired dimensions corresponding to a shape and dimensions of a standard utility device.  
   
   
       6 . The masonry block of  claim 5 , wherein the standard utility device comprises an electrical system junction box.  
   
   
       7 . The masonry block of  claim 5 , wherein the standard utility device comprises a heating, ventilating and air conditions system device.  
   
   
       8 . The masonry block of  claim 5 , wherein the standard utility device comprises a plumbing system device.  
   
   
       9 . An assembly comprising: 
 a masonry block molded by a masonry block machine employing a mold assembly having a plurality of liner plates, at least one of which is moveable; the masonry block comprising: 
 a first transverse face;  
 a second transverse face opposing the first transverse face;  
 at least one aperture extending through the masonry block between the first and second transverse faces;  
 a first end face joining the first and second transverse faces;  
 a second end face opposite the first end face and joining the first and second transverse faces;  
 a first major face joining the first end and second end faces;  
 a second major face opposing the first major face and joining the first and second end faces;  
 a molded utility opening extending through the first major face to the at least one aperture, wherein the first major face and molded utility opening are formed during a molding process by action of a moveable liner plate having a mold element which is a negative of the molded utility opening; and  
 a utility assembly installed at least within the molded utility opening.  
   
   
   
       10 . The assembly of  claim 9 , wherein a portion of the utility assembly extends into and through the at least one aperture.  
   
   
       11 . The assembly of  claim 9 , wherein the moveable liner plate is moved by a gear drive assembly.  
   
   
       12 . The assembly of  claim 9 , wherein the utility assembly comprises an electrical system assembly.  
   
   
       13 . The assembly of  claim 9 , wherein the electrical system assembly comprises a junction box installed within the molded utility opening.  
   
   
       14 . The assembly of  claim 13 , wherein the electrical system assembly further includes at least one conduit stub extending from the junction through the at least one aperture.  
   
   
       15 . The assembly of  claim 9 , wherein the utility assembly comprises a heating, ventilating and air conditioning system assembly.  
   
   
       16 . The assembly of  claim 9 , wherein the utility system comprises a plumbing system assembly.  
   
   
       17 . The assembly of  claim 16 , wherein the plumbing system assembly comprises a pipe extending through the molded utility opening and through the at least one aperture.  
   
   
       18 . A method of producing a masonry block having a first major face and an opposing second major face, a first transverse face and a second opposing transverse face, and a first end face and an opposing second end face, the method comprising: 
 providing a mold assembly having a plurality of liner plates that form a mold cavity having an open top and an open bottom and including a core bar assembly, wherein at least a first liner plate is moveable between a retracted position and an extended position and includes a mold element which is a negative of a desired molded utility opening;    moving the first liner plate to the extended position;    closing the bottom of the mold cavity with a pallet;    filling the mold cavity with dry cast concrete via the open top;    closing the top of the mold cavity with a shoe assembly;    compacting the dry cast concrete to form a procured masonry block with the second transverse face resting on the pallet, wherein the core bar assembly forms at least one aperture between the first and second transverse faces, and wherein the mold element forms the desired molded utility opening extending from the first major face to the aperture, the molded utility opening adapted to receive a utility device.    
   
   
       19 . The method of  claim 18 , further comprising: 
 moving the first liner plate to the retracted position;    expelling the pre-cured masonry block from the mold cavity; and    curing the pre-cured masonry block.    
   
   
       20 . The method of  claim 18 , wherein the first liner plate is moved between the retracted and extended positions using a gear drive assembly.