Patent ID: 7208112
Filing Date: 2007-04-24
Classification: B28B,B29B,B29C,E04B,E04C

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