Masonry blocks and method of making masonry blocks having overlapping faces

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 including a first transverse face, a second transverse face opposing the first transverse face, a first major face joining the first transverse face to the second transverse face, a second major face opposing the first major face and joining the first transverse face to the second transverse face, a first end face joining the first major face to the second major face, and a second end face opposing the first end face and joining the first major face to the second major face, wherein the first end face comprises a non-planar face configured to engage and overlap with a non-planar end face of a similar masonry block and is formed during a molding process through action of a moveable liner plate having a negative of the non-planar end face.

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;    a first major face joining the first transverse face to the second transverse face;    a second major face opposing the first major face and joining the first transverse face to the second transverse face;    a first end face joining the first major face to the second major face; and    a second end face opposing the first end face and joining the first major face to the second major face, wherein the first end face comprises a non-planar face configured to engage and overlap with a non-planar end face of a similar masonry block and is formed during a molding process through action of a moveable liner plate having a negative of the non-planar end face.    
   
   
       2 . The masonry block of  claim 1 , wherein the second end face comprises a non-planar face configured to engage and overlap with a non-planar end face of a similar masonry block and is formed during a molding process through action of a moveable liner plate having a negative of the non-planar end face.  
   
   
       3 . The masonry block of  claim 1 , wherein at least one of the first and second major faces includes a desired three-dimensional pattern which is imprinted during the molding process through action of a moveable liner plate having a negative of the desired three-dimensional pattern.  
   
   
       4 . The masonry block of  claim 1 , wherein the non-planar face of the first end face is formed by a flange extending between the first and second major faces along an edge shared with the second transverse face, the flange defining a substantially parallel notch extending between the first and second major faces along an edge shared with the first transverse face, wherein the flange is configured to engage a notch and overlap with a flange of an end face of a similar masonry block.  
   
   
       5 . The masonry block of  claim 4 , wherein the second end face is non-planar and formed by a flange extending between the first and second major faces along an edge shared with the second transverse face, the flange defining a substantially parallel notch extending between the first and second major faces along an edge shared with the first transverse face, wherein the flange is configured to engage a notch and overlap with a flange of an end face of a similar masonry block.  
   
   
       6 . The masonry block of  claim 4 , wherein the second end face is non-planar and formed by a flange extending between the first and second major faces along an edge shared with the first transverse face, the flange defining a substantially parallel notch extending between the first and second major faces along an edge shared with the second transverse face, wherein the flange is configured to engage a notch and overlap with a flange of an end face of a similar masonry block.  
   
   
       7 . The masonry block of  claim 1 , further including one or more apertures extending through the masonry block from the first transverse face to the second transverse face.  
   
   
       8 . A retaining wall 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 retaining wall block comprising: 
 a top face;    a bottom face opposing the top face;    a front face joining the top face to the bottom face;    a rear face opposing the front face;    a set-back flange extending from the bottom face along at least a portion of an edge shared with the rear face and formed by action of a moveable shoe assembly during a molding process;    a first side face joining the front and rear faces; and    a second side face opposite the first side face and joining the front and rear faces, where at least one of the first and second side faces comprises a non-planar face configured to engage and overlap with a non-planar end face of a similar retaining wall block and is formed during a molding process through action of a moveable liner plate having a negative of the non-planar face.    
   
   
       9 . The retaining wall block of  claim 8 , wherein the first and second side faces are angled such that a width of the front face is greater than a width of the rear face.  
   
   
       10 . The retaining wall block of  claim 8 , wherein the front face includes a desired three-dimensional pattern which is imprinted during the molding process through action of a moveable liner plate having a negative of the desired three-dimensional pattern.  
   
   
       11 . The retaining wall block of  claim 8 , wherein the first side face comprises a non-planar face and is formed by a flange extending between the front and rear faces along an edge shared with the bottom face, the flange defining a substantially parallel notch extending between the front and rear faces along an edge shared with the top face, wherein the flange and notch are formed through action of a moveable liner having a negative of the flange and notch, and wherein the flange is configured to engage a notch and overlap with a flange of an end face of a similar retaining wall block.  
   
   
       12 . The retaining wall block of  claim 11 , wherein the second side face comprises a non-planar face and is formed by a flange extending between the front and rear faces along an edge shared with the top face, the flange defining a substantially parallel notch extending between the front and rear faces along an edge shared with the bottom face, wherein the flange and notch are formed through action of a moveable liner having a negative of the flange and notch, and wherein the flange is configured to engage a notch and overlap with a flange of an end face of a similar retaining wall block.  
   
   
       13 . The retaining wall block of  claim 8 , wherein the first side face comprises a non-planar face and is formed by a flange extending between the front and rear faces along an edge shared with the top face, the flange defining a substantially parallel notch extending between the front and rear faces along an edge shared with the bottom face, wherein the flange and notch are formed through action of a moveable liner having a negative of the flange and notch, and wherein the flange is configured to engage a notch and overlap with a flange of an end face of a similar retaining wall block.  
   
   
       14 . The retaining wall block of  claim 13 , wherein the second side face comprises a non-planar face and is formed by a flange extending between the front and rear faces along an edge shared with the bottom face, the flange defining a substantially parallel notch extending between the front and rear faces along an edge shared with the top face, wherein the flange and notch are formed through action of a moveable liner having a negative of the flange and notch, and wherein the flange is configured to engage a notch and overlap with a flange of an end face of a similar retaining wall block.  
   
   
       15 . A method of producing a masonry block having a first major face and an opposing second major face, a first transverse face and an opposing second transverse face, and a first end face and a 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, wherein at least a first liner plate is moveable between a retracted position and an extended position, the first moveable liner plate including a negative of a desired non-planar face;    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 pre-cured masonry block with the first transverse face resting on the pallet, wherein the first moveable liner plate forms the desired non-planar face in the first end face, the desired non-planar face configured to engage a non-planar face of a similar masonry block;    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.    
   
   
       16 . The method of  claim 15 , wherein a second liner plate is moveable between a retracted position and an extended position, the second liner plate being generally opposite the first liner plate and including a negative of a desired non-planar face, the method including moving the second liner plate to the extended position subsequent to compacting the dry cast concrete such that desired non-planar face is formed in the second end face, the desired non-planar face configured to engage a non-planar face of a similar masonry block.  
   
   
       17 . The method of  claim 15 , wherein compacting the dry cast concrete includes forming a set-back flange extending from the second transverse face along an edge shared with the second major face by providing a notch in the shoe assembly.  
   
   
       18 . The method of  claim 15 , wherein compacting the dry cast concrete includes forming one or more hollow cores extending through the masonry block from the first transverse face to the second transverse face.  
   
   
       19 . The method of  claim 15 , wherein a second liner plate is moveable between a retracted position and an extended position, the second liner plate including a negative of a desired three-dimensional pattern, the method including moving the second liner plate to the extended position subsequent to compacting the dry cast concrete such that desired non-planar face is formed in the first major face.  
   
   
       20 . The method of  claim 15 , wherein the first moveable liner plate forms a desired non-planar face comprising a flange and a substantially parallel notch extending from the first major face to the second major face, the flange configured to engage a notch and overlap a flange in an end face of a similar masonry block.  
   
   
       21 . The method of  claim 15 , wherein the first liner plate is moveable between the retracted and extended positions using a gear drive assembly.