Patent ID: 7807083
Filing Date: 2010-10-05
Classification: B28B,B29B,B29C,E04B,E04C

Abstract:
1. A method of making a plurality of concrete blocks having different three dimensional patterned faces, comprising the steps of: selecting a plurality of different three-dimensional patterns of one or more existing objects; digitally scanning the different selected three-dimensional patterns to create different scanned data in XYZ coordinates that is representative of each of the different selected three-dimensional patterns; creating from each of the different scanned data in the XYZ coordinates a different digital data set for each of the different three-dimensional patterns, the digital data sets being representative of the plurality of different desired three dimensional patterned faces of the concrete blocks based on the scanned data of the different three-dimensional patterns; using the digital data set for each of the different three-dimensional patterns to create a plurality of different mold surfaces each having a three-dimensional pattern that is the mirror image of one of the plurality of different desired three dimensional patterned concrete block faces, each of the three-dimensional patterns on the mold surfaces having a maximum relief of at least about 0.5 inches; providing a plurality of molds each having a plurality of side walls defining a mold cavity, each of the molds including one of the plurality of different mold surfaces with the mirror image of the desired three-dimensional patterned concrete block face; introducing dry cast concrete into each of the mold cavities; compacting the dry cast concrete in each of the mold cavities to form a plurality of pre-cured concrete blocks, wherein during compaction, the different desired three-dimensional patterned faces are imparted to the pre-cured concrete blocks by the mold surfaces with the mirror image of the plurality of different desired three dimensional patterned concrete block faces; discharging each of the pre-cured concrete blocks from the respective mold cavity; and curing each of the pre-cured concrete blocks.