Method of making a concrete block

Abstract

Molds and processes that permit high-speed, mass production of retaining wall blocks having patterned or other processed front faces, as well as retaining wall blocks formed by such processes. The invention permits the front face of the block to be impressed with a pattern or otherwise directly processed, to allow the formation of pre-determined block front faces, while at the same time facilitating high-speed, high-volume production of blocks. A mirror image of the desired pattern can be created on a stripper shoe by selecting a desired three-dimensional surface from a naturally occurring or man made object and digitally scanning the selected three-dimensional pattern to create scanned data. The scanned data can then be used to machine a face of the stripper shoe that is the mirror image of the selected pattern.

What is claimed is: 
     
         1 . A mass produced dry cast concrete masonry block suitable for use in building soil retaining walls, comprising:
 an upper face;   a lower face suitable for engaging said upper face of an adjacent block to maintain a generally parallel relationship between the upper faces of blocks in successive courses of blocks when the blocks are stacked together to form a wall;   a patterned front face that joins said upper and lower faces, the pattern having been imparted to the front face of the block during the molding process by the action of a moveable stripper shoe having a mirror image of the patterned front face;   a rear face;   a first generally vertical side face joining said front and rear faces;   a second generally vertical side face opposed to the first side face and joining said front and rear faces; and   a flange extending below said lower face of the block to provide a surface suitable for engaging the block with the rear face of a different block in the course below said block to thereby provide a pre-determined set-back to a retaining wall constructed from such block.   
     
     
         2 . The masonry block of  claim 1 , wherein a first converging portion of said first side face converges towards said second side face as the side faces extend toward said rear face, and wherein said first converging portion is formed by a moveable mold surface during the molding process. 
     
     
         3 . The masonry block of  claim 2  further including a second converging portion of said second side face, that converges towards said first side face as the side faces extend toward said rear face, and wherein said second converging portion is formed by a moveable mold surface during the molding process. 
     
     
         4 . The masonry block of  claim 1  wherein the front face of the block is generally vertical. 
     
     
         5 . The masonry block of  claim 1  wherein the front face is oriented so that its upper edge where it intersects the upper face of the block is closer to the rear face of the block than is its lower edge where it intersects the lower face of the block. 
     
     
         6 . The masonry block of  claim 4  wherein the upper edge of the front face is closer to the rear face of the block than is its lower edge by a distance which is approximately equal to the pre-determined set back. 
     
     
         7 . The masonry block of  claim 1 , wherein at least a portion of each side face is textured during the molding process. 
     
     
         8 . The masonry block of  claim 1 , wherein said patterned front face of said block has a relief of at least 0.5 inches. 
     
     
         9 . A mass produced dry cast concrete masonry block suitable for use in building soil retaining walls, comprising:
 an upper face;   a lower face suitable for engaging said upper face of an adjacent block to maintain a generally parallel relationship between the upper faces of blocks in successive courses of blocks when the blocks are stacked together to form a wall;   a patterned front face that joins said upper and lower faces, the pattern having been imparted to the front face of the block during the molding process by the action of a moveable stripper shoe having a mirror image of the patterned front face;   a rear face;   a first generally vertical side face joining said front and rear faces;   a second generally vertical side face opposed to the first side face and joining said front and rear faces; and   wherein a first converging portion of said first side face converges towards said second side face as the side faces extend toward said rear face, and wherein said first converging portion is formed by a moveable mold surface during the molding process.   
     
     
         10 . The masonry block of  claim 9  further including a second converging portion of said second side face opposite said first converging portion of said first side face, said second converging portion converging towards said first side face as the side faces extend toward said rear face, and wherein said second converging portion is formed by a moveable mold surface during the molding process. 
     
     
         11 . The masonry block of  claim 9  wherein the front face of the block is generally vertical. 
     
     
         12 . The masonry block of  claim 9  wherein the front face is oriented so that its upper edge where it intersects the upper face of the block is closer to the rear face of the block than is its lower edge where it intersects the lower face of the block. 
     
     
         13 . The masonry block of  claim 11  wherein the upper edge of the front face is closer to the rear face of the block than is its lower edge by a distance which is approximately equal to the pre-determined set back. 
     
     
         14 . The masonry block of  claim 9 , wherein at least a portion of each side face is textured during the molding process. 
     
     
         15 . The masonry block of  claim 9 , wherein said patterned front face of said block has a relief of at least 0.5 inches.