Abstract:
A method for forming a concrete masonry block having external plates. The external plates with anchors are indexed on pallets that are fed into concrete casting machines by proper location of the plates. Concrete mixture is deposited inside of a mold and compressed into the mold with anchors being located in the concrete material and having at least one external plate. Thereafter, the concrete masonry block with the external plate is removed from the mold and cured.

Description:
CONTINUATION-IN-PART 
     This application is a Continuation In Part of Application Ser. No. 08/908,841 filed Aug. 8,1997, now U.S. Pat. No. 5,809,732. 
    
    
     DISCLOSURE OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to concrete masonry blocks and more particularly to concrete masonry blocks that have external plates anchored through the blocks. Further, the invention relates to a method of constructing a wall having concrete masonry blocks with external plates at predetermined locations so that heavy objects can be supported from the external plates secured in concrete masonry blocks in the wall. A method for forming concrete masonry blocks with external plates and internal anchors is also shown. 
     2. Brief Description of the Prior Art 
     Concrete masonry blocks have been used in the building of buildings throughout most industrialized countries of the world. Concrete masonry blocks come in many different sizes and shapes. A typical rectangular concrete masonry block used in building a wall will have two external faces so that when the concrete masonry block is installed in the wall, the external faces will be on either side of the wall. Internally, within the concrete masonry blocks, a pair of vertical holes extend upward through the concrete masonry blocks. Typically, one end of the concrete masonry block is fluted and the other end of the concrete masonry block is smooth. The width of the concrete masonry block may vary depending on the strength desired in the wall. 
     In government buildings, especially prisons, concrete masonry blocks are used because they are structurally strong, functional, and are easy to maintain. However, in many governmental buildings, especially prisons, it is important to be able to anchor items to the wall, which items would not touch the floor. In the past, it has been a very labor intensive process to suspend items from the wall. For example, a hole will have to be drilled through concrete masonry blocks forming the wall and anchor plates installed on either side of the wall. The anchor plates would have to be installed in a way that would not be easily removable. The installing of anchor plates in the wall after the wall is built is very time consuming, labor intensive, and expensive. 
     Just some of the things that are typically attached to the wall that would require anchor plates would be shelf hooks, privacy panels, grab bars, bunk beds, sliding devices, mounting of doors, television stands, or ceiling plates. These are only some of the items that may have to be attached to the wall in a governmental facility such as a prison. 
     There is a long felt unmet demand for better ways to attach to concrete walls throughout the industrialized countries of the world. It may be a facility such as a public restroom, cafeteria, school, or any other similar facility that needs to be structurally strong, functional, and easy to maintain. Any public facility that has items suspended from the wall rather than sitting on the floor is much easier to clean and maintain. 
     Fricker, U.S. Pat. No. 5,197,255, shows an anchoring device for attaching flat panels to a wall. The Fricker patent does not appear to be that close to the present invention. 
     Kline, U.S. Pat. No. 5,402,616, shows the imbedding of a metal weldment into the concrete slab structure. Again, this patent does not appear to be very close to the present invention. 
     Parkes, U.S. Pat. No. 3,236,545, shows a replacement block that is used for electrical outlets and conduits. Parker does not talk about supporting items from the wall structure. 
     Woodruff, U.S. Pat. No. 4,414,674, shows an electric furnace thermal insulating module that does not appear to be close to the present invention. 
     The patents cited hereinabove were the patents found in the patentability search conducted by applicant. None of the prior art found by applicant suggests in any way the anchoring of external plates to the surface of concrete masonry blocks with internal anchors during the forming of the concrete masonry blocks. 
     Dec-Tech, Inc. from Covington, Louisiana, has been offering for sale a steel block that can be substituted for a concrete masonry block. The steel blocks by Dec-Tech, Inc. are not formed with concrete. Also, because the steel blocks do not have concrete, the Dec-Tech, Inc. steel blocks do not have anchors extending through concrete to hold the plates in position. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to show concrete masonry blocks having an external plate or plates that are anchored in the concrete at the time the concrete masonry block is formed. 
     It is another object of the present invention to have a series of different types of concrete masonry blocks having external plates anchored therethrough, the design of the external plate and the concrete masonry blocks depending on the needs of the end user. 
     It is a further object of the present invention to have a series of concrete masonry blocks with external plates and anchors extending therethrough, such concrete masonry blocks include the following: 
     a. Full length, double sided plates with end caps. 
     b. Half length, double sided plates with end caps. 
     c. Full length, double sided plates. 
     d. Half length, double sided plates. 
     e. Full length, single sided plates. 
     f. Half length, single sided plates. 
     g. Half blocks with full length, double sided plates and end caps. 
     h. Half blocks with double sided plates. 
     i. Upper half, single sided plates. 
     j. Full length, double sided plates with different anchor designs. 
     k. Full length, single sided plates with different anchor designs. 
     It is a further object of the present invention to provide other designs of external plates on concrete masonry blocks having anchors formed within the concrete masonry blocks at the time of casting. 
     It is yet another object of the present invention to construct a wall having external plates at various locations in the wall to which items can be suspended from the wall. 
     It still another object of the present invention to determine the type of external plate that is needed and to include the particular type of external plate in the wall at the time of construction of a wall to support items from the wall. 
     It is yet another object of the present invention to provide a method of forming concrete masonry blocks having external plates and embedded anchors at the time of casting the concrete masonry blocks so that when the concrete masonry blocks are cured, the external plates are securely anchored to the external surface of the concrete masonry blocks. 
     It is yet another object of the present invention to provide indexing for positioning the external plates and anchors within molds used to form the concrete masonry blocks. 
     A concrete casting machine using a mold and supporting pallet is normally used to form concrete masonry blocks. In the present invention, the supporting pallet feeds into the concrete casting machine, and while the casting machine is open, external steel plates and anchors are placed at predetermined locations on the supporting pallet. The mold is then either lowered into position on the supporting pallet with the external plates and anchors being received inside of the mold or raised into position replacing the supporting pallet. The latter method is made possible where the external plates and anchors are secured from the sides via electromagnets. Concrete mix is used to fill the mold box. Normally the mold is vibrated to insure the concrete fills up all of the voids in the mold box. 
     Next, the compression portion of the mold pushes down into the mold box to compress the concrete mix in the desired shape of a block having external plate or plates with internal anchors. The mold is stripped from the concrete masonry block, the concrete masonry block is removed from the concrete casting machine, and the concrete masonry block is moved to the kiln chamber for heating and solidifying the concrete. The anchors are formed inside the concrete masonry block at the time it is made with the external plates being on the external surface or surfaces of the concrete masonry block. 
     A wide variety of different types of blocks with external plates can be made. The only limitation is the expense and cost to the end user. 
     When building a wall that needs external plates for attachment of items to the wall, the wall will be built using normal concrete masonry blocks, but at predetermined locations, blocks with external plates will be installed. Thereafter, items to be suspended from the wall can be anchored to the plate by any convenient means such as welding, though other types of anchoring devices could be used. 
     By use of external plates already anchored in preformed concrete masonry blocks, the large amount of time, labor, and expense involved in installing plates for suspension of items from the wall has been eliminated. While the concrete masonry blocks with external plates, known as M-Bed Block Systems, is a more expensive block, it more than makes up for the cost differential in the reduced labor and costs. As is known by those skilled in the art, the concrete masonry wall should be reinforced by pouring concrete in the center openings and having reinforcing rods in the poured concrete. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIGS. 1 a  through  1   c  are depictions of some possible variations in anchor styles. 
     FIGS. 2 a  through  21  are a series of perspective views of different types of concrete masonry blocks made according to the present invention with the internal anchors being shown in broken lines. 
     FIGS. 3 a  through  3   c  are the top plane view, front elevational view, and end view of the concrete masonry block illustrated in FIG. 2 c.    
     FIGS. 4 a  through  4   g  are planned perspective views of sections of walls utilizing different concrete masonry blocks made according to the present invention. 
     FIG. 5 is a perspective view of a concrete casting machine used to form concrete masonry blocks made according to the present invention. 
     FIGS. 6 a  and  6   b  are perspective views of a supporting pallet containing indexing to properly locate the external plates and anchors on the supporting pallet prior to insertion into a mold of a concrete masonry blocks casting machine. 
     FIGS. 7 a  and  7   b  are exploded perspective views of the upper and lower portions of the mold with the supporting pallet and external plates and anchors prior to being inserted into the mold box. 
     FIG. 8 is a partial perspective view illustrating positioning of external plates and anchors on the supporting pallet prior to being received in a mold box of a concrete masonry casting machine. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     First, the applicant will describe some of the many different types of concrete masonry blocks that can be formed with external plates anchored through the concrete masonry blocks. Second, a detailed description of one of the many blocks will be given as further reference. Third, illustrative sections of walls will be shown to demonstrate how M/Bed Blocks made according to the present invention would be used. Fourth, how the M/Bed Blocks that have external plates and internal anchors are formed will be illustrated and discussed in a series of views. 
     In FIG. 2 a,  a full length block  10  is shown with double sided external plates and end cap  12 . The full length block  10  has vertical holes  14  and  16  therein as is standard in most blocks. One end of the full length block  10  has flutes  18  on either side thereof. 
     Imbedded in the concrete of the full length block  10  are four identical  20 . The anchors  20  depicted here are of the type shown in FIG. 1 a.  The anchors  20  are welded to the left side  24  and right side  26  of the double sided external plates and end cap  12 . The anchors  20  are shown as perpendicularly extending between the external plates but the could alternatively be at an obtuse angle with respect to said plates  12  (see FIGS. 2 g  and  2   h ). The anchors  20  located at the fluted end  28  are imbedded in the fluted concrete  30 . The anchors  20  located at the center of the full length block  10  are imbedded in the center concrete  32 . 
     The end cap  34  is formed integrally with the left side  24  and right side  26  of the double sided external plates and end cap  12 . While the double sided external plate and end cap  12  may vary in thickness and material, it is presently envisioned that {fraction (3/16)} inch thick steel plates will be used. The top edge of these steel plates may have a chamfer  45  (see FIG. 3 c ) which is an inclination of about 45° sloping downward to the interior space of the full length block. Such an inclination at this edge may accommodate receipt of concrete during the molding process and contribute to an eventual flushness of the steel plates with the external concrete portions of the M/Bed block. The types of anchors and the thickness thereof can vary. However, it is currently envisioned that the anchors  20  will be either {fraction (3/16)} inch steel plates in the configuration as shown in FIG. 1 a,  ribbed re-bar as shown in FIG. 1 b,  or {fraction (3/16)} inch steel plates cut to the configuration as shown in FIG. 1 c.    
     In referring to the subsequent FIGS. 2 b  through  21 , the same numbers that were used to designate the same parts in connection with FIG. 2 a  will be used for subsequent figures. Only the parts that are different will be described in detail hereinbelow. 
     In FIG. 2 b,  a full length block  10  is shown that has half length, double sided plates with end caps  36 . Again, the anchors  20  extend through the center concrete  32  and are welded on either end to the left side  38  and right side  40  of the half length, double sided plates  36 . The end cap  34  is the same as previously described. 
     Because the left side  38  and right side  40  of half length, double sided plates  36  are placed in the concrete masonry at the same time the full length block  10  is formed, the external surfaces of the block are basically smooth even at the terminal end  42  of the left side  48  and right side  40  of half length, double sided plates  36 . 
     In FIG. 2 c,  a full length block  10  is shown with double sided external plates with a left plate  44  and a right plate  46 . The left plate  44  and the right plate  46  are connected together by anchors  20  welded to the respective left plate  44  or right plate  46 . The anchor  20  on the fluted end  28  extends through fluted concrete  30 . Anchors  20  that are in the middle extend through the center concrete  32 . Anchors  20  that are on the flat end  48  of full length block  10  extend through flat end concrete  50 . 
     In FIG. 2 d,  a full length block  10  is shown with double sided half plates having a left half plate  52  and a right half plate  54 . Anchors  20  that are located at the center of the full length block  10  extend through the center concrete  32 . Anchors  20  that are at the flat end  48  extend through the flat end concrete  50 . Again, the anchors  20  are connected to the left half plate  52  and the right half plate  54  by welding the ends thereto. 
     FIG. 2 e  shows a full length block  10  with a full length, single sided plate  56 . The anchors  58  are made from an appropriate size steel to withstand the stress. It is believed that {fraction (3/16)} inch steel cut and bent to the configuration as shown will withstand the stress. However, anchors of other styles may be used. The anchors  58  only have end lips  22  on the right side of the full length, concrete masonry block  10 . The anchors  58  are abutted against and welded to the full length, single sided plate  56 . The anchors  58  at the fluted end  28  extend through fluted concrete  30  with the end lips  22  being imbedded in concrete on the right side of the full length block  10 . Likewise, anchors  58  at the center of full length concrete masonry block  10  extend through center concrete  30  with the end lips  22  being imbedded in concrete on the right side of full length block  10 . The anchors  58  located on the flat end  48  of the full length block  10  extend through the flat end concrete  50  with the end lips  22  being anchored in concrete on the right side of full length block  10 . 
     In FIG. 2 f,  a full length block  10  is shown with a single sided, half length plate  60 . Anchors  58  are welded to the single sided plate  60  with the center anchors extending though center concrete  32  and the flat end anchors  58  extending through flat end concrete  50 . Again, the end lips  22  are imbedded in the concrete on the right hand side of the full length concrete masonry block  10 . Additionally, the single sided, half length plate with anchors may be in the form of an end cap positioned at the end of a block (not shown). 
     Alternatively, as shown in FIG. 2 g  and FIG. 2 h,  use of anchors  20  of the type depicted in FIG. 1 c  could provide sufficient support when attached to plate  56  or plate  60  near its center and angled toward the opposing corners of the full length block  10 . This particular embodiment adds to the overall soundness and strength of structure of the completed concrete masonry block in two ways. First, obtuse anchors  20  aid in securing the plate  56  (or alternatively plate  60 ) attached thereto within the structure of the completed block. Second, utilizing an anchor  20  of a type having a nonuniform surface (as depicted in  1   b  or  1   c ) aids in securing the anchor itself within the completed block. 
     FIG. 2 i  shows a half length block  62  that has double sided, external plates with end cap  64 . Anchors  66  extend through the fluted concrete  30  at the fluted end  28  and are welded on either end thereof to the left side  68  and the right side  70  of the double sided, external plates with end caps  64 . The double sided external plates  64  have an end cap  72  similar to the end cap shown in FIG. 2 a.    
     FIG. 2 k  shows a half length block  62  having double sided, external plates made up of left side  68  and right side  70 . Again, anchors  66  are welded on either end thereof to either the left side  68  or the right side  70  of the external plates. On the fluted end  28 , the anchor  66  extended through the fluted concrete  30 . On the flat end  48 , the anchors  66  extend through the flat end concrete  50 . In both FIGS. 2 i  and  2   j,  a vertical hole  74  extends upward through the half length block  62 . 
     In FIG. 2 j,  a full length block  10  is shown with an upper half, single sided plate  76 . Anchors  58  hold the upper half, single sided plate  76  in position. The anchors  58  extend through fluted concrete  30 , center concrete  32 , and flat end concrete  50 . Anchors  20  of the type depicted in FIG. 1 b  are shown, but alternate anchors may be used. The end lips  22 , of the anchor type shown, are imbedded in the concrete on the right hand side of full length block  10 . The anchors  58  are welded to the upper half, single sided plate  76 . The anchors  20  may be angled other than perpendicularly with respect to the upper half, single sided plate  76 . 
     FIG. 21 shows a full length concrete masonry block  10  with single sided plate  46  on one side and an upper half single sided plate  76  on the other side. The lower anchors  58  have end lips  22  to hold in the concrete. Upper anchors  66  used in FIG. 21 consist of a flat piece of metal cut and welded to plate  46  and plate  76 . Again, the anchors  66  are imbedded in fluted concrete  30 , center concrete  32 , and flat end concrete  50 . Alternatively, the lower anchors may be of the types depicted in FIGS. 1 b  and  1   c  and may be angled toward the lower corner of block  10  opposite the single sided plate  46 . 
     To illustrate in more detail the physical construction of one of the concrete masonry blocks shown in FIGS. 2 a  through  21 , FIG. 2 c  has been selected for illustration purposes. Referring to FIGS. 3 a, b,  and  c  in combination, the physical layout of a typical concrete masonry block having external steel plates is illustrated. Again, the same numbers will be used as were used in FIG. 2 c  for illustration purposes. The anchors  58 , as they connect from left plate  44  to right plate  46 , are clearly illustrated. Also, the burying of the anchors  58  in either the fluted concrete  30 , center concrete  32 , or flat end concrete  50  is also illustrated. Additionally, a 45° chamfer  45  is shown. By viewing FIGS. 2 a  through  c  in combination, the physical structure of a typical block having external plates and anchors as shown in the present invention is clearly illustrated. 
     Assume that blocks such as illustrated in FIGS. 2 a  through  21  have been made. The purpose of FIGS. 4 a  through  4   g  is to illustrate how those blocks would be used in a typical wall. Like numbers that are used to illustrate wall sections will be used in all of the FIGS. 4 a  through  4   g.  Only a short section of the wall will be illustrated to demonstrate the different types of uses of blocks having external plates as shown in the present invention. 
     Referring to FIG. 4 a,  a block wall section  80  is illustrated. The plain blocks  82  do not have any external plates formed therein. However, two blocks are made according to the present invention and have external plates  84 . The external plates  84  are at a height that is typically used to mount shelves. Shelf hooks would be welded or anchored to external plates  84  by any convenient means. In the typical block wall section  80 , the wall would need to be poured and reinforced with reinforcing rods to maintain the structural integrity of the wall. This is especially true when an object of heavy weight is to be supported from the external plates  84 . 
     Block wall section  80  as shown in FIG. 4 b  has a total of four half plates  86 . The half plates  86  are arranged in such a configuration that two of the half plates are located one above the other with the other two half plates being on the same plane, but a few feet apart. The half plates  86  as illustrated in FIG. 4 b  are of a typical height on which a television stand could be mounted. By simply attaching mounting brackets to the half plates  86 , a television stand could then be supported by the block wall section  80 . Again, all the remainder of the blocks will be plain concrete masonry blocks  82 . 
     Referring to FIG. 4 c,  half plates  86  are mounted in the wall and arranged so that they are paired with each pair having two half plates in a vertical arrangement. All of the pairs of half plates  86  are on the same plane. The configuration as shown in FIG. 4 c  is arranged at a typical height so that bunk beds could be attached to the wall  80 . By welding or attaching appropriate hooks to the half plates  86 , bunk beds could then be suspended from the wall  80 . Again, the remainder of the blocks could be plain concrete masonry blocks  82 . 
     FIG. 4 d  shows a wall section  80  constructed primarily of plain blocks  82 , but having two half plates  86  arranged a couple of feet from the bottom of the wall. The half plates  86  are in the same plain and would typically be used to attach grab bars thereto. 
     In FIG. 4 e,  a wall section  80  is illustrated constructed primarily of plain concrete masonry blocks  82 . However, in FIG. 4 e,  vertical rows  88  of half plates  86  are shown. The vertical rows  88  are used to attach privacy panels or other types of dividers as may typically be used in restrooms. 
     Referring to FIG. 4 f,  the wall section  80  is shown that has a doorway  92  located therein. Surrounding the doorway are a combination of full length blocks having half length, double sided plates with end caps  36  and half length blocks having double sided, external plates with end caps  64 . The door structure (not shown) would be attached to the combination of half length, double sided plates with end caps  36  and the double sided, external plates with end caps  64 . 
     If the door is a sliding door, the lower part could have a full length, double sided external plate and end cap  12  with full length, double sided plate  94 . 
     At the top of the doorway  92 , full length, double sided plates  94  may be mounted in a row. These full length, double sided plates  94  that are mounted in the horizontal row at the top of the doorway  92  can be used for a number of different purposes. First, if the door is a sliding type door, it can be used to mount the door (not shown). Second, if some type of sliding device needs to be suspended from the wall, full length, double sided plates  94  provide an excellent way to mount the sliding devices. While FIG. 4 f  has been described as full length, double sided plates  94 , they could be single sided, full length plates. 
     FIG. 4 g  shows a corner section  96  of a typical wall utilizing the present invention. In the corner section  96 , there are two horizontal rows  98  and  100  of full length plates made according to the present invention. The horizontal row  100  of the external plates could be used to mount sliding devices thereto. The upper horizontal row  98  would be what is typically used in prisons to mount ceiling plates to prevent escape of the prisoners. 
     It should be realized that any number or combination of external plates made according to the present invention could be installed in the wall depending on what the end user wants to accomplish with the invention. 
     FIG. 5 shows a typical concrete masonry block casting machine illustrated by reference numeral  102 . While many different types of casting machines could be used, for the purposes of the present illustration, a Fleming machine is illustrated. However, concrete casting machines made by Columbia or Besser could also be used. Concrete mix  104  is stored in a hopper  106 . The concrete mix  104  feeds from the hopper  106 , on the belt conveyor  108 , to the intake  110  of the concrete casting machine  102 . 
     Pallets  112  also feed into the casting machine  102  by means of conveyor  114 . Mold  116  is positioned in the concrete casting machine  102  in the conventional way. Mold  116  determines the type of concrete masonry block being case. The operation of the concrete casting machine  102  is typical with the exception of the portions described hereinbelow. 
     Referring to FIGS. 6 a  and  6   b,  perspective views of a typical pallet  112  that would be used to form concrete masonry blocks according to the present invention are shown. The pallet  112  may have a combination of rounded humps  118 , as in FIG. 6 a,  that would typically extend about one eighth of an inch high. Alternatively, the pallet  112  may have a combination of depressed grooves  119  carved therein, as in FIG. 6 b,  that could be of a one eighth inch depth. The rounded humps  118 , or the depressed grooves  119 , can then be used to position the external plates on the pallet  112 . For example, a double sided external plate with end cap  12  is illustrated on pallet  112  of FIGS. 6 a  and  6   b.  The double sided external plate and end cap  12  is pushed securely against the corner humps  120  and the side humps  122  or pushed securely into the depressed grooves  119  as in FIG. 6 b.    
     The humps  120  and  122  are inside the steel plates in FIG. 6 a.  If outside, the mold  116  must be indented to accommodate the humps  120  and  122 . If inside, the concrete in the formed block will contain an indentation when formed, but the indentation will be filled with mortar when the block is installed in a wall. 
     Inside of the concrete masonry casting machine  102 , the external plates and/or anchors must be located inside of the mold  116 . Referring to FIG. 7, an exploded perspective view of how the external plates and molds fit together is illustrated. As FIG. 7 shows, an external plate (double sided with end cap shown  12 ) is positioned on the pallet  112  within the depressed grooves  119 . Alternatively, the pallet  112  may be of the type securing the double sided, external plate and end cap with corner humps  120  and side humps  122  (not shown in FIG.  7 ). When the lower part of the mold box  124  moves down, the double sided, external plates and end cap  12  are received inside of the mold box  124 . If it is necessary to secure the double sided, external plates and end cap  12  in position, electromagnets  126  may be included in the mold box  124  to aid in securing external plates  12 . The electromagnets may also allow for the securing of external plates  12  in the absence of the pallet  112 . This mold securing means could be used in securing external plates whether or not the plates were of the double sided with end cap  12  (as shown) configuration. 
     Once the lower part of the mold box  124  is filled, the upper portion of the mold  128  comes down and presses the concrete mix to form a block in the desired shape as dictated by the mold  116  including the lower part  124  and upper part  128 . 
     Between the making of concrete masonry blocks by the concrete casting machine  102 , the number and shape being determined by the mold  116 , the operator must position the external plates into position on the pallet  112 . In the Fleming machine, it is open for a period of time during which the steel plates may be inserted and positioned on the pallet  112 . This is illustrated in FIG.  8 . The pallet also must rest in a very accurate position against side rails  130  and against a stop  132  so that everything is properly aligned with the mold  116 . The stop  132  may be lowered by motor  134  when the cast masonry blocks are to be removed.