Abstract:
A mold, process of using the mold to form a block, and the resultant block are disclosed. The block may of course be connected to other blocks to form stuctures such as walls. The blocks and structures may have curved features for simulating a log structure. The mold and process utilize cemititious material for forming a the block, which has a pair of block members, one of which has a curved outer face. The block members are separated by a central insulation space and connected by rods extending from each block member across the central insulation space. The mold has a body including a pair of block forming cavities. Each cavity has a material ingress-egress opening adapted to receive a block forming composition and to output a block. The block forming cavities are separated a predetermined distance by a space forming central cavity. The mold also has a block ejector movably connected to the body. The ejector has a plate member associated with each cavity, and a handle. The blocks disclosed include pair of block members, one of which has a curved outer face. The block members are separated by a central insulation space and connected by at least one block connector extending from each block member across the central insulation space.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates, generally, to concrete block structures and methods, and concrete blocks and methods. Particularly, the invention relates to buildings, walls and other structures constructed of concrete blocks and having the appearance of a log structure; method of making such structures; concrete blocks having the appearance of log portions; methods of making and using such blocks; and apparatus and methods for making such structures and blocks. The invention is particularly useful for constructing a building such as a residential home or the like which is strong, decorative, efficient, long lasting, and economical to build and maintain.  
         [0003]     2. Background Information  
         [0004]     The state of the art includes various building structures, structural building elements, and building and manufacturing methods and apparatus, including those relating to concrete.  
         [0005]     This technology is believed to have significant limitations and shortcomings, including but not limited to that they are not strong, decorative, efficient, long lasting, and economical to build and maintain, either individually or in combination.  
         [0006]     For this and other reasons, a need exists for the present invention.  
         [0007]     All US patents and patent applications, and all other published documents mentioned anywhere in this application are incorporated by reference in their entirety.  
       BRIEF SUMMARY OF THE INVENTION  
       [0008]     The invention provides buildings and other structures constructed of concrete blocks and having the appearance of a log structure; methods of making such structures; concrete blocks having the appearance of log portions; methods of making and using such blocks; and apparatus and methods for making such structures and blocks which are practical, reliable, accurate and efficient, and which are believed to fulfil the need and to constitute an improvement over the background technology.  
         [0009]     A mold, process of using the mold to form a block, and the resultant block are disclosed. The block may of course be connected to other blocks to form stuctures such as walls. The blocks and structures may have curved features for simulating a log structure. The mold and process utilize cemititious material for forming a the block, which has a pair of block members, one of which has a curved outer face. The block members are separated by a central insulation space and connected by rods extending from each block member across the central insulation space. The mold has a body including a pair of block forming cavities. Each cavity has a material ingress-egress opening adapted to receive a block forming composition and to output a block. The block forming cavities are separated a predetermined distance by a space forming central cavity. The mold also has a block ejector movably connected to the body. The ejector has a plate member associated with each cavity, and a handle. The blocks disclosed include pair of block members, one of which has a curved outer face. The block members are separated by a central insulation space and connected by at least one block connector extending from each block member across the central insulation space.  
         [0010]     In one aspect, the invention provides a mold comprising a body including a pair of block forming cavities each having a material ingress-egress opening adapted to receive a block forming composition and to output a block, the block forming cavities being separated a predetermined distance by a space forming central cavity; and a block ejector movably connected to the body and including a plate member associated with each cavity, and a handle.  
         [0011]     In a more particular aspect, the invention provides a mold for cemititious material for forming a block having a pair of block members, one of which has a curved outer face, the block members being separated by a central insulation space and connected by rods extending from each block member across the central insulation space, comprising:  
         [0012]     a. a body including: 
        i. a first body member having an inner wall member disposed adjacent the central cavity, a curved outer wall member, and a pair of side wall members connecting the outer and inner wall members at oppose ends, the wall members of the first body member defining a first block forming cavity of a predetermined configuration, the first block forming cavity having a material ingress-egress opening adapted to receive a block forming composition and to output a first formed block member, and an ejector plate opening disposed at an end of the block forming cavity opposite the ingess-egress opening;     ii. a second body member having an inner wall member disposed adjacent a central cavity between the first block forming cavity of the first body member, an outer wall member, and a pair of side wall members connecting the outer and inner wall members at oppose ends, the wall members defining a second block forming cavity of a predetermined configuration, the second block forming cavity having a material ingress-egress opening adapted to receive a block forming composition and to output a second block member, and an ejector plate opening disposed at an end of the second block forming cavity opposite the ingess-egress opening, the first and second block forming cavities being separated a predetermined distance by the space forming central cavity;     iii. a pair of connector plates which connect the first and second body members to each other at opposite ends, the connector plates mating with the side wall members of the first and second body members; and        
 
         [0016]     b. a block ejector movably connected to the body and including a plate member associated with each cavity, and a handle.  
         [0017]     In another aspect, the invention provides a method of making a block comprising the steps of: 
        a. providing a mold comprising a body including a pair of block forming cavities each having a material ingress-egress opening adapted to receive a block forming composition and to output a block, the block forming cavities being separated a predetermined distance by a space forming central cavity; and a block ejector movably connected to the body and including a plate member associated with each cavity, and a handle;     b. adding block forming composition into each block forming cavity through the respective material ingress-egress opening;     c. placing at least one connecter in the block forming composition of one block forming cavity and extending it across the space of the central cavity to the block forming compostion of the other block forming cavity;     d. ejecting a block from the mold; and     e. curing the block;        
 
         [0023]     In a further aspect, the invention provides a block for use in building a structure, comprising a pair of block members, one of which has a curved outer face, the block members being separated by a central insulation space and connected by at least one block connector extending from each block member across the central insulation space.  
         [0024]     The features, benefits and objects of the invention will become clear to those skilled in the art by reference to the following description, claims and drawings. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING  
       [0025]      FIG. 1  is a perspective view of an embodiment of a mold of the present invention for making an embodiment of the building block of the present invention.  
         [0026]      FIG. 2  is a perspective view of the mold of  FIG. 1 , shown inverted and ready to receive a concrete mixture to produce a full block with an interior curved face and an exterior curved face.  
         [0027]      FIG. 3  is a perspective view of the mold of  FIG. 2 , further showing a half block insert (one operatively placed and the other being placed) for producing a half block, with interior and exterior curved faces.  
         [0028]      FIG. 4  is a perspective view of the mold of  FIG. 2 , further showing an interior wall, flat wall insert being placed, for producing a full block with a curved exterior face and an interior flat face.  
         [0029]      FIG. 5  is a perspective view of the mold of  FIG. 4 , further showing the interior wall, flat wall insert operatively placed for producing a full block with a curved face and a flat face.  
         [0030]      FIG. 6  is a perspective view of the mold of  FIG. 4 , further showing half block inserts placed on the curved wall forming cavity and being placed in the flat wall cavity.  
         [0031]      FIG. 7  is a side elevation view of the mold of  FIG. 2 .  
         [0032]      FIG. 8  is a top plan view of the mold of  FIG. 2 .  
         [0033]      FIG. 9  is a bottom view of the mold of  FIG. 2 .  
         [0034]      FIG. 10  is an end view of the mold of  FIG. 2 .  
         [0035]      FIG. 11   a  illustrates a pair of blocks produced by a mold of the present invention, the blocks being full blocks and having curved interior and exterior faces.  
         [0036]      FIG. 11   b  illustrates a pair of blocks produced by a mold of the present invention, the blocks being full blocks and having a curved exterior faces and an flat interior faces.  
         [0037]      FIG. 11   c  illustrates a block produced by a mold of the present invention, the block being full and having flat interior and exterior faces.  
         [0038]      FIG. 12  is a perspective view of plural courses of blocks laid to construct a wall of a building or other structure.  
         [0039]      FIG. 13  is a perspective view of an embodiment if a discharge member of a mold, the discharge member further having a cut-out member disposed thereon for producing a utility enclosure in a block.  
         [0040]      FIG. 14  is a perspective view of a mold with a concrete input guide operatively disposed thereon.  
         [0041]      FIG. 15  is a perspective view of the input guide.  
         [0042]      FIG. 16  is a perspective view of the input guide of  FIG. 15 , shown inverted.  
         [0043]      FIG. 17  shows application of a coat or layer of cementitious material to the outer surface of the laid blocks to enhance the log appearance of the structure.  
         [0044]      FIG. 18  shows a portion of a complete block structure.  
         [0045]      FIG. 19  is a perspective view of an embodiment of the mold of the present invention, constructed and arranged to produce a block having flat interior and exterior walls.  
         [0046]      FIG. 20  illustrates a block produced by the mold of  FIG. 19 .  
         [0047]      FIG. 21  shows a paddle type mixer system for making concrete and loading the mold.  
         [0048]      FIG. 22  is another view thereof.  
         [0049]      FIG. 23  shows an output area thereof.  
         [0050]      FIG. 24  shows the cart and mold adjacent the output area.  
         [0051]      FIG. 25  shows the cart and mold thereof.  
         [0052]      FIG. 26  is anothe view of the cart and mold.  
         [0053]      FIG. 27  shows a bender and metal for bending metal inserts.  
         [0054]      FIG. 28  shows a close up view of an insert being bent in the bender. 
     
    
     DETAILED DESCRIPTION  
       [0055]     The invention provides, in general:  
         [0056]     1. buildings and other structures constructed of concrete blocks and having the appearance of a log structure;  
         [0057]     2. methods of making such structures; concrete blocks having the appearance of log portions;  
         [0058]     3. methods of making and using such blocks; and  
         [0059]     4. apparatus and methods for making such structures and blocks.  
         [0060]     The benefits of the invention include, but are not necessarily limited to, in general:  
         [0061]     1. the building or other structure produced with the blocks is strong, storm proof, waterproof, and resistant to decay and insect damage,  
         [0062]     2. the building or other structure produced with the blocks is decorative, having the appearance of being constructed of logs instead of concrete blocks or poured concrete,  
         [0063]     3. the building or other structure produced with the blocks is efficient to build, use, heat and maintain,  
         [0064]     4. the building or other structure produced with the blocks is long lasting, and  
         [0065]     5. the building or other structure produced with the blocks is economical to build, use, heat and maintain.  
         [0066]     Referring to  FIGS. 1, 2 , and  7 - 10 , an embodiment of a mold  10  of the present invention includes a body formed by a pair of body members  11  a and b and a press  12 . The body members  11  and press  12  are preferably constructed of metal, such as steel. The mold  10  is initially disposed as shown in  FIG. 2  to receive a cemititous composition such as cement. The composition may be compacted, for example by vibrating. Thereafter, the mold  10  is inverted as shown in  FIG. 1 . Thereafter, the press  12  is pushed downward to eject a wet block. The block is cured, for example by setting a predetermined period of time to form a complete, dry, rigid block, for example block  50  shown in  FIG. 11A .  
         [0067]     The mold  10  body members  11   a  and  b  preferably comprise a inner wall  23 , an outer wall  24 , and side walls  27 . The inner wall  23  is preferably substantiall flat, while the outer wall  24  has a major curved face portion  25  and a minor flat face portion  25 . The side walls  26  connect the inner and outer walls  23  and  24 , preferably at a right angle. Each body  11  has a wide opening  18  forming a block forming cavity, and for ingress of concrete and egress of the cured block, and a narrow bottom opening  19  for insertion of the press  12 . Each body member  11  also preferably has a pair of complementary, parallel, mating connector panels  28 , which are substantially flat and have a predetermined length extending away from it&#39;s respective inner wall  23 . The bodies  11   a  and  b  are further connected by connection panels  31  and  32  at opposite ends. The connector panels  31  and  32  are shown to be substantially flat and have a predetermined dimension. Panels  28 ,  31  and  32  preferably have a plurality of slots for adjustable mating by connectors  35 . Connectors  35  are preferably bolts, but may be screws or other fasteners. The bodies  11  are therefore adjustably separated by a central insulation space  17 , which is open at its top and bottom ends. Inner walls  23  have aligned, vertically oriented slots  21 , which are open at one end (See  FIG. 2 ). The slots  21  permit placement of connectors such as metal rods (for example, common rebar material) plastic, fiberglas or other rigid or semi-rigid material into the concrete mixture in each body  11  cavity, which connectors extend across the central space  17  and connect the block bodies shown in  FIG. 11A  for example.  
         [0068]     The curved surface of face  25  preferably forms a quarter cylinder configuration, which forms the outer surface of one block  50 . This surface is preferably mated with another block to form a half or hemi cylinder structure  83  as shown for example in  FIG. 12 . Plural courses of structures  83  and  84  are preferably mated to form a wall  80  or other structure having the general appearance of one being formed of logs or timbers. The faces  25  preferably have one or more (preferably three) ribs  22 . Two outer ribs are shown to be permanently affixed to the faces  25 , while a center rib is removable, and affixed with a screw  37  through aperture  38 . The ribs  22  form stucco grooves  55  in the face  54  of the resultant blocks  50  as shown in  FIG. 11A  for example. Side walls  27  preferably have connection ribs  20  which form mortar grooves  57  in the sides of the blocks  50  also shown in  FIG. 11A . The bottom portion of the bodies  11  generally at flat faces  26  form course supporting edges  56  in blocks  50  shown in  FIG. 11A . Space  17  forms insulation space  53  in the blocks  50  of  FIG. 11A . Rods  52  extend accross space  53  between block members  51   a  and  b.  The faces  25  also preferably have one or more plugs or blocks  46 , shown in  FIGS. 7, 8  and  10 , disposed in the flat area  26  which extend through the cavity to create apertures  47  in the formed block body  50 , as shown in  FIG. 11B . The apertures  47  permit injection of insulation or other material into the space  53  from the exterior.  
         [0069]     Handles  33  and  34  are connected to the connection plates  31  and  32 . The handles  33  and  34  have a predetermined extension length and serve as stands or legs for the mold  10  when it is in a concrete receiving mode as shown in  FIG. 2 , and serve as manual grasping and lifting means when the mold  10  is in a block ejection mode as shown in  FIG. 1 .  
         [0070]     Press  12  includes a pair of flat press panels  39  which are connected by press handles  40  and  41 . The panels  39  have a predetermined dimension which corresponds to the area of the body  11  openings  19 , and serve as a bottom concrete containment surface during curing. During block ejection, the handles  40  and  41  are pressed downward (relative to  FIG. 1 ). Panels  39  preferably have one or more slots  42  which permit movement of the panel  39  around ribs  22 .  
         [0071]     An alternative embodiment of the press  95  is shown in  FIG. 13  for forming a utility cutout in a wall. The utility cut out may be used to place electrical or plumbing hardware in a block located in a predetermined location on a wall or other structure. The cutout may be disposed on an interior or exterior wall, provided it is a flat wall. The press  95  comprises a pair of panels  96   a  and  b,  a material holding frame  99 , in the form of a rectangular box, for example, and a pair of handles  97  and  98 . The frame holds back material inserted in a mold to form a cavity in the resultant block (not shown).  
         [0072]      FIG. 3  shows optional half block inserts  13  being deployed and deployed in openings  18  b and a of mold  10 . Inserts  13  are held in place by fasteners  37 , for example screws, disposed through apertures  38 . The half block inserts  13  can be used to form blocks which are one half the size of a normal block  50 . The inserts  13  is swappable with center rib  22 .  
         [0073]      FIGS. 4 and 5  show an optional flat wall insert  14  being deployed and fully deployed in opening  18  of mold  10  to create a flat inside and a curved outside surface in body  11   b.  The resulting block  60  is shown for example in  FIG. 11B  with curved exterior surface member  61  and flat wall member  62  spanned by rods  63 . The flat surface can be used for an interior wall or any other wall or surface which is desired to be flat in contrast to log-shaped. Inserts  14  preferably have a vertical wall  43 , a horizontal ledge  44  and a lip  45 . Alternatively, if a pair of flat walls is desired, an alternative embodiment of the mold  90  is shown in  FIG. 19  with a pair of rectilinear shaped cavities  91   a  and  b.  Here, no insert is required. Mold  60  generates block  70  with two flat surfaces  71  and  72  shown in  FIGS. 11   c  and  20 .  
         [0074]      FIG. 6  shows an optional half block separator  16  which is intended to span the width of flat space  15  of for example  FIG. 5 .  
         [0075]     In use, the mold  10  is initially disposed as shown in  FIG. 2  to receive a cemititous composition such as cement. After addition of cement and any compaction via vibration or the like, the mold  10  is inverted as shown in  FIG. 1 . The press  12  is pushed downward to eject a block therefrom. The block is then cured, preferably by setting a predetermined period of time. Cement or other material may be shoveled or poured directly in the openings  18   a  and  b.  Alternatively, guide  100  shown in  FIGS. 14, 15  and  16  may be placed on a mold (in this example, dual flat wall mold  90 ) to aid placement. Guide  100  includes a collar  101  and a divider fin  102  which forms apertures  103  a and b which align with openings  18   a  and  b.    
         [0076]     FIGS.  11  A-C show exemplary block embodiments of the present invention, which are preferably formed by the mold embodiments discussed above. Block  50  shown in  FIG. 11A  is formed by mold  10  described above. The block  50  includes a pair of bodies  51   a  and  b,  one or more rods, shafts or connectors  52  extending between the bodies  51   a  and  b  connecting and separating them a predetermined distance, and an insulation space  53  between the bodies  51   a  and  b  of the predetermined width distance. Each body  51  has a curved outer or exterior face  54  preferably in the form of a quarter cylinder configuration. Grooves  55  are preferably made in face  54  to aid in holding stucco or other surface finishing compounds or materials. A score line  58  may be made in the bodies  51  to permit breaking of block  50 ′ into half blocks (not shown).  FIG. 11B  shows a block  60  comprising a curvilinear surface body  61  and a flat surface body  62  connected via rods  63 . Score line  68  may be added to aid in forming half blocks from full block  60 ′. This block  60  is preferably formed by mold  10  utilizing flat wall insert  14 .  FIG. 11C and 23  show block  70  comprising two flat surface bodies  71  and  72  connected by rods  73 . Score line  78  may be added to aid in forming half blocks from full block  70 ′. Surface grooves (not shown) are optional. This block  70  may be formed by mold  10  utilizing an insert  14  disposed in each body  11 . Alternatively, it may be formed by mold  90  shown in  FIG. 22 , which has rectilinear forming cavities  91   a  and  b.    
         [0077]     Referring to  FIG. 12 , structures such as wall  80  are formed by plural stacked courses  81 , for example  81   a  and  81   b,  each of which is made up of plural side by side blocks  82 , each of which is in turn formed by stacked lower and upper block halves  50   a  and  b.  The curved, quartercylinder surface  54  of block  50 A is mated with that of block  50 B to form a half or hemi cylinder composite block  82  structure, which resembles a segment of a half log on each side. Additional composite of full blocks  82 ′,  82 ″,  82 ′″,  82 ″″ are placed next to or side by side each other (abuting ends  57 ) to form a course  81   a  of blocks. Plural courses of structures  81   a,    82   b  and the line may be mated to form a wall  80  or other structure having the general appearance of one being formed of logs or timbers. Grooves  55  are preferably disposed in the blocks  50  to aid in retention of stucco  89  or other optional surface finishes, for example shown being manually applied in  FIG. 17  to building  120 . Stucco or other material may also be sprayed on by means of a sprayer. Courses of blocks may further be modified or adjusted to form log comer structures for example as shown in  FIG. 18 . Mortar grooves  57  are preferably disposed in the sides of the blocks  50  to improve the side by side connection between the blocks in a course. Flat course supporting edges  56  in blocks  50  improve stacking of courses. Space  17  forms insulation space  53  in the blocks  50  of  FIG. 11A . Rods  52  extend accross space  53  between block members  51   a  and  b.    
         [0078]     As was discussed above, cemetitious material may be placed into molds, optionally with the aid of funnels or guides, such as funnel  100  shown in  FIGS. 14-16 .  
         [0079]     Alternatively, referring to  FIGS. 21-26  show a block making system comprising mold cart  110  and mixer  114 . A mold, for example mold  10  is placed on cart  110  and transported to the mixer  114 . Mold  10  is connected to holder  111  attached to mixer  110  adjacent to chute  112 . Holder preferably is constructed and arranged to connect to an electric motor to vibrate and thus compact material output in the mold. The material (not shown) is placed in mixer  114  via it&#39;s top and mixed to a predetermined consistency and then output via the chute  112 , where it is placed in the mold  10 . Thereafter, the cart  110  is used to transport the mold.  10  to a drying area for block ejection subsequent to curing. Plural molds may be used to substantially continuously produced blocks.  
         [0080]      FIGS. 30 and 31  disclose an embodiment of a rod shaping device of the present invention.  
         [0081]     Further, blocks may be produced by an extrusion or other mass production process.  
         [0082]     The descriptions above and the accompanying drawings should be interpreted in the illustrative and not the limited sense. While the invention has been disclosed in connection with an embodiment or embodiments thereof, it should be understood by those skilled in the art that there may be other embodiments which fall within the scope of the invention as defined by the claims. Where a claim, if any, is expressed as a means or step for performing a specified function it is intended that such claim be construed to cover the corresponding structure, material, or acts described in the specification and equivalents thereof, including both structural equivalents and equivalent structures, material-based equivalents and equivalent materials, and act-based equivalents and equivalent acts.  
         [0000]     embodiments which fall within the scope of the invention.