Patent Publication Number: US-2013251936-A1

Title: Dual-Face Dual-Split Concrete Product

Description:
CROSS-REFERENCE(S) TO RELATED APPLICATION(S) 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/613,483, filed Mar. 20, 2012, all of which is hereby incorporated by reference to the extent not inconsistent with the disclosure herewith. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
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     REFERENCE(S) TO MICROFICHE APPENDIX AND/OR COPYRIGHT PROTECTION 
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     BACKGROUND 
     1. Field 
     In general, the inventive arrangements relate to concrete products, and, more specifically, to a dual-face dual-split concrete block that is particularly useful when constructing and/or arranging landscaping elements. 
     2. Description of Related Art 
     For illustrative, exemplary, representative, and non-limiting purposes, preferred embodiments of the inventive arrangements will be described in terms of landscaping elements. However, the inventive arrangements are not limited in this regard. 
     Now then, concrete products are well-known landscaping elements, and they are often used as a preferred way to construct and/or arrange retaining walls, landscaping wails, etc. As such, they are often assembled in courses, with each course comprising a plurality of such concrete products. 
     SUMMARY 
     In one embodiment, a dual-face dual-split concrete product comprises a first face of horizontal length X and an opposing second face of horizontal length Y, the first face and second face being substantially parallel to one another according to a trapezoidal shape, and with X&gt;Y; generally opposing sidewalk that taper in from the first face to the second face; and generally opposing top and bottom faces adjoining the first face, second face, and opposing sidewalk, with the to face and bottom face being substantially parallel to one another; wherein the first face has one or more subfaces, including one or more inner subfaces intermediate two outer subfaces, with the inner subfaces having a horizontal length L substantially equal to the horizontal length Y of the second face as measured across the concrete product. 
    
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
       A clear conception of the inventive arrangements, and of various construction and operational aspects of typical mechanisms provided by such arrangements, are readily apparent by referring to the following illustrative, exemplary, representative, and non-limiting figures, which form an integral part of this specification, in which like numerals generally designate the same elements in the several views, and in which: 
         FIG. 1A  is an exaggerated top view of a concrete block according to the inventive arrangements; 
         FIG. 1B  is a front view of the concrete block of  FIG. 1 ; 
         FIG. 1C  is a back view of the concrete block of  FIG. 1 ; 
         FIG. 2A  is a top view of a single ingot formed from a mold for use in accord with the inventive arrangements; 
         FIG. 2B  is the same ingot of  FIG. 2A , representatively showing six concrete products of  FIG. 1  arranged in a conjugate, alternating arrangement, particularly prior to separation therebetween into individual concrete blocks in accord with the inventive arrangements; 
         FIG. 3  is a top view of multiple adjacent ingots, such as of  FIG. 2 ; 
         FIG. 4A  is a top view of a top knife for cutting three adjacent ingots in accord with the inventive arrangements; 
         FIG. 4R  is a top view of bottom knife in mating alignment with the top knife of  FIG. 4A ; 
         FIG. 5A  is a top view of a top knife for cutting n adjacent ingots in accord with the inventive arrangements; 
         FIG. 5B  is a top view of a bottom knife in mating alignment with the top knife of  FIG. 5A ; and 
         FIG. 6  is a simplified, composite top view of various knife cuts overlaying three multiple adjacent ingots advancing over time. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring now to the figures, preferred embodiments of the inventive arrangements will be described in terms of landscaping elements. However, the inventive arrangements are not limited in this regard. 
     Now then, referring to  FIGS. 1A-1C , a three dimensional concrete block  10  has an approximate trapezoidal shape  12  (parallel lines shown in phantom) when viewed from a top view ( FIG. 1A ). The concrete block  10  has a first face  14  and an opposing second face  16 , the first face  14  and second face  16  being generally parallel to one another in orientation according to the trapezoidal shape  12 . Preferably, the first face  14  and second face  16  are joined by opposing side walls  18  connecting therebetween. Preferably, a horizontal length of the first face  14  (X) is longer than a horizontal length of the second face  16  (Y) as measured between the sidewalls  18  across the concrete block  10 —i.e., X&gt;V. As a result, the opposing sidewalls  18  generally taper in from the first face  14  to the second face  16  when shown in top view ( FIG. 1A ) due to the first face  14  being longer in horizontal length than the second face  16  (i.e., X&gt;Y) as measured across the concrete block  10 . A generally perpendicular distance between the first face  14  and second face  16  defines a general depth D of the concrete block  10 . 
     The first face  14  and second face  16 , as well as the sidewalls  18 , are further joined by a top face  20  and generally opposing bottom face  22 , with a generally perpendicular distance between the top face  20  and bottom face  22  defining a general height H of the concrete block  10 . 
     Distinctions between the first face  14  and the second face  16 , as well as between the top face  20  and the bottom face  22 , are arbitrary reference indicators for simplicity only; they may be altered and/or interchanged therebetween as desired. 
     In addition, the concrete block  10  is suitably dimensioned according to preferred dimensions, depending, far example, on one or more desired applications for the concrete block  10 , suitably chosen by those skilled in these arts. 
     Now then, referring to  FIGS. 2A-2B , a single ingot  24  is farmed from a concrete mold (mold not shown) for use in accord with the inventive arrangements. More specifically, one or more of the concrete blocks  10  of  FIG. 1  (such as, preferably, six concrete blocks  10   a - 10   f ) are shape-molded in a conjugate, alternating arrangement within the ingot  24 , with generally adjacent first faces  14   a - 14   f  and generally adjacent second faces  16   a - 16   f  to be formed between alternating concrete blocks  10   a - 10   f  according to the inventive arrangements (with exceptions, for example, at the ends  26   a ,  26   f  of the ingot  24  for a non-adjacent first face  14   a  of an ending concrete block  10   a  and a corresponding non-adjacent first face  14   f  of another ending concrete block  10   f ). The ends  26   a ,  26   f  of the ingot  24  are waste pieces, not generally forming a part of the concrete blocks  10   a ,  10   f . Preferably, waste components are minimized. In any event, the concrete blocks  10   a - 10   f  of the single ingot  24  are shown prior to physical separation therebetween, and the ingot  24  is preferably of any suitable length, likely largely dependent on a chosen mold (mold not shown) suitably chosen by those skilled in these arts. 
     Referring now to  FIG. 3 , multiple ingots  24  of  FIG. 2  are adjacent to one another, such as two adjacent ingots  24   a - 24   b , three adjacent ingots  24   a - 24   c , and/or more adjacent ingots  24   a - 24   n  (with an n th  ingot representatively comprising n adjacent ingots  24 ). Preferably, adjacent ingots  24   a - 24   n  are molded simultaneously with one another, such as by mold forming techniques known in these arts. Preferably, the ingots  24   a - 24   n  are suitably spaced apart from one another by a suitable mold distance M, but they are also preferably brought into physical contact with one another (i.e., M=0) by known clamping techniques at the outer peripheries of the multiple ingots  24   a - 24   n  when cutting the concrete blocks  10   a - 10   f  according to the inventive arrangements. 
     Preferably, the individual concrete blocks  10   a - 10   f  are cut and separated from one another along both the first faces  14   a - 14   f  and the second faces  16   a - 16   f . Accordingly, each concrete block  10   a - 10   f  is dual-faced: both the first face  14  and the second face  16  of the concrete block  10  comprise outwardly facing faces of same, split according to the inventive arrangements and later preferably arranged as desired (e.g., into retaining walls, landscaping walls, etc.). 
     Likewise, each concrete block  10   a - 10   f  is also dual-split: they are cut and separated along both their first faces  14  and their second faces  16  of the concrete block  10 , again split according to the inventive arrangements and later preferably arranged as desired (e.g., into retaining walls, landscaping walls, etc.). 
     Now then, referring to  FIGS. 4-5 , a cutting assembly  28  is used to cut the bigots  24   a - 24   n  of  FIGS. 2-3  along the first faces  14   a - 14   f  and the second faces  16   a - 16   f  of the concrete blocks  10   a - 10   f . More specifically, the cutting assembly  28  cuts the ingots  24   a - 24   n  to define the first faces  14   a - 14   f  and the second faces  16   a - 16   f  of the concrete blocks  10   a - 10   f , thereby forming the dual-face dual-split concrete blocks  10  of  FIGS. 1A-1C . 
     By the inventive arrangements, the same cutting assembly  28  cuts both the first faces  14   a - 14   f  and the second faces  16   a - 16   f  within the ingots  24   a - 24   n . In other words, the single cutting assembly  28  is used to cut along both the first faces  14   a - 14   f  and the second faces  16   a - 16   f  of the ingots  24   a - 24   n . Even more specifically, the cutting assembly  28  is contoured to cut according; to both the first faces  14   a - 14   f  of the concrete blocks  10   a - 10   f  as well as the second faces  16   a - 16   f  of the concrete blocks  10   a - 10   f.    
     Accordingly, a single cutting assembly  28  can be used to cut both the first faces  14   a - 14   f  and the second faces  16   a - 16   f  of the ingots  24   a - 24   n  into the concrete blocks  10   a - 10   f  of the inventive arrangements. Preferably, the cutting assembly  28  comprises a top knife  30   a  and a bottom knife  30   b  in mating alignment therewith. The two knifes  30  are brought into close physical proximity with one another under suitable force to sever one ingot  24  or multiple adjacent ingots  24   a - 24   n  according to the described contours of the cutting surfaces  32  of the knives  30 . In one preferred embodiment (e.g.,  FIG. 4 ), a single cut by the cutting assembly  28  cuts three adjacent ingots  24   a - 24   c . In another preferred embodiment (e.g.,  FIG. 5 ), a single cut by the cutting assembly  28  cuts a adjacent ingots  24   a - 24   n.    
     The dual-face dual-split concrete block  10  is thereby cut by the single cutting assembly  28  of  FIGS. 4-5 . More specifically, as the one or more ingots  24   a - 24   n  advance along a conveyor or the like (not shown), the cutting assembly  28  cuts the concrete blocks  10   a - 10   f  along each of the first faces  14   a - 14   f  and each of the second faces  16   a - 16   f  of respective concrete blocks  10   a - 10   f . Because of the conjugate, alternate arrangement of the ingots  24   a - 24   n , each cut has a desired, and alternating, effect on particular concrete blocks  10 . Accordingly, the knifes  30  cut, at different times, the different faces  14 ,  16  of the different ingots  24   a - 24   n , particularly depending on a particular ingot  24  arrangement, including multiple adjacent ingots  24   a - 24   n . For example, depending on a particular cut, a knife  30  cuts a first face  14   a  of a concrete block  10   a  at a first time t 1  along a single ingot  24   a , then cuts a second face  16   a  of the same concrete block  10   a  at a second time t 2  along the same single ingot  24   a . This second cut at time t 2  also forms the second face  16   b  of the next concrete block  10   h  along that same ingot  24   a . Likewise, a third cut at time t 3  forms the first face  14   b  of the next concrete block  10   h , and simultaneously the first face  14   c  of the next concrete block  10   c  along the same ingot  24   a . This pattern continues for cutting the length of the single ingot  24   a  over an appropriate number of time intervals and cuts. 
     At the same time, because the knifes  30  also span multiple ingots  24   a - 24   n , the first cut at time t 2  also cuts the second face  16  of an adjacent ingot  241 , as well as a first face  14  of another adjacent ingot  24   c . This pattern also continues for cutting any number of adjacent bigots  24   a - 24   n.    
     As described, the knives  30  make the same cuts at each time interval. However, because of the alternating arrangements of the concrete blocks  10  to be formed—both along a single ingot  24 , as well as across multiple ingots  24   a - 24   n  different, and alternating, first faces  14  and second faces  16  of the various concrete blocks  10  are formed, oftentimes simultaneously. Sometimes the knives  30  will contact an ingot  24  and form (i) a first face  14  only (ii) a second face  16  only; (iii) simultaneous first faces  14  of alternate concrete blocks  10 ; (iv) simultaneous second faces  16  of alternate concrete blocks  10 ; and/or (v) ends  26 . And sometimes, at least part of the cutting surfaces  32  of the knives  30  will not contact a particular part of an ingot  24  at all and instead hit a void space in the cutting, process for that particular cut. Preferably, the number of cuts the cutting assembly  28  will make depends on how many concrete blocks  10  are to be formed from one or more ingots  24   a - 24   n , such as determined by the lengths of the ingots  24   a - 24   n . Usually, there will be one more cut than the number of concrete blocks  10  to be formed from a single ingot  24 . For example, in  FIG. 6 , each ingot  24   a - 24   n  forms six concrete blocks, for which there are seven cuts along each ingot  24   a - 24   n . Two of the cuts, namely the first cut at time t 1  and the last cut at time t 7  form, in part, part of the ends  26   a ,  26   f  of the respective ingots  24   a - 24   n.    
     Preferably, the opposing sidewalls  18  of the ingots  24   a - 24   n , as well as the top faces  20  and the bottom faces  22  thereof, are formed by the molds of the ingot-making process—the inventive arrangements then defining the first faces  14  and second faces  16  thereof. 
     Referring again to  FIGS. 1A-1C , the concrete block  10  has an approximate trapezoidal shape  12  (parallel lines shown in phantom). As previously described, a horizontal length of the first face  14  (X) is preferably longer than a horizontal length of the second face  16  (Y) as measured across the concrete block  10 —i.e., X&gt;Y. Preferably, each first face  14  of the concrete block  10  comprises at least three or more subfaces  34  as well, including one or more inner subfaces  34   b - 34   d  intermediate two outer subfaces  34   a ,  34   e . Preferably, the one or more inner subfaces  34   b - 34   d  are of a total horizontal length L substantially equal to the horizontal length of the second face  16  (Y) as measured across the concrete block—i.e., L=Y. In other words, by the inventive arrangements, the total horizontal length L of the inner subfaces  34   b - 34   d  is approximately equal to the horizontal length of the second face  16  (Y). In addition, these subfaces  34  are preferably contoured to match one another, as will be elaborated upon. In addition, the desired subfaces  34   a - 34   e  of the first face  14  are formed from the contours of the cutting assembly  28  and knives  30 , as are subfaces  36   b - 36   d  (see below) of the second face  16 . These matching contours are seen in the cutting surfaces  32  of the top views of the bottom knives  30   h  in  FIGS. 4B and 5B  (with the top knives  30   a  being in mating alignment with the bottom knives  30   b ). 
     Preferably, each of the two outer subfaces  34   a ,  34   e  is of a horizontal length  6 , with L+G+G=X as measured across the first face  14  of the concrete block  10 . In other words, by the inventive arrangements. G is approximately equal to (X−L)/(2). In addition, the two outer subfaces  34   a ,  34   e  are generally aligned with one another and substantially parallel to the second face  16  in relation to the trapezoidal shape  12 , and the second face  16  is shorter in horizontal, length (Y) than the first face  14  (X) by approximately (2)*(G). 
     Preferably, each second face  16  of the concrete block  10  also comprises at least three or more subfaces  36   b - 366  as well. Preferably, the subfaces  36   b - 366  are of a horizontal length Y as previously described. Preferably, the subfaces  36   b - 366  of the second face  16  are respectively contoured to match the inner subfaces  34   b - 34   d  of the first face  14  (see, e.g., FIG.  1 A). Again, these matching contours can also be seen in the cutting surfaces  32  of the top views of the bottom knives  30   b  in  FIGS. 4B and 5B  (with the top knives  30   a  being in mating alignment with the bottom knives  30   b ). Preferably, at least one or more of these subfaces  36   b ,  36   d  are generally aligned with one another and substantially parallel to the first face  14  in relation to the trapezoidal shape  12 . Preferably, two or more of the inner subfaces  34   b - 34   d  of the first face  14  are also substantially parallel to the subfaces  36   b - 36   d  of the second face  16 . 
     Preferably, transitions between the faces of the concrete block  10  are tumbled to soften the look thereof, such as between the first face  14  and the top face  20 , the first face  14  and the bottom face  22 , the second face  16  and the top face  20 , and the second face  16  and the bottom face  22 , etc. 
     Preferably, there is an odd number of subfaces  34  of the first face  14 , such as three or five or seven or nine, etc. In another alternative embodiment, there is an even number of subfaces  34  of the first face  14 , such as two or four or six or eight, etc. Preferably, the two most external subfaces  34   a ,  34   e  are substantially aligned with one another as shown in  FIG. 1 ), with the inner subfaces  34   b - 34   d  connecting the two most external subfaces  34   a ,  34   e . In another alternative embodiment, the two most external subfaces  34   a ,  34   e  are not substantially aligned with one another, but again with the inner subfaces  34   b - 34   d  connecting the two most external subfaces  34   a ,  34   e  (although this changes the conjugate arrangement of the concrete blocks  10  of the ingots  24   a - 24   n ). Likewise, there is also, preferably, an odd number of subfaces  36  of the second face  16  as well, such as three or five or seven or nine, etc. In another alternative embodiment, there is an even number of subfaces  36  of the second face  16 , such as two or four or six or eight, etc. Preferably, the two most external subfaces  36   b ,  36   d  are substantially parallel with one another (as shown in  FIG. 1 ), with the inner subface  36   c  connecting the two most external subfaces  36   b ,  36   d . In another alternative embodiment, the two most external subfaces  36   b ,  36   d  are not substantially parallel with one another, but again with the inner subface  36   c  connecting the two most external subfaces  36   b ,  36   d  (although this again changes the conjugate arrangement of the concrete blocks  10  of the ingots  24   a - 24   n ). 
     In a preferred embodiment, the inner subfaces  34   b - 34   db  of the first face  14  match the subfaces  36   b - 36   d  of the second face  16  (see, e.g.,  FIG. 1A ). 
     Referring now generally to  FIG. 6 , each of the concrete blocks  10  is substantially identical to the other concrete blocks  10 , with conjugate concrete blocks  10  each facing opposing directions, both within a single ingot  24 , as well as across adjacent ingots  24   a - 24   n . More specifically, with each successive cut of the cutting knife  28  (e.g., cuts  17 ) as adjacent ingots  24   a - 24   n  advance together, the first faces  14  of one concrete block  10   a  become the second faces  16  of the next concrete block  10   b  along a particular ingot  24 . In addition, a single cut from the cutting assembly  28  cuts along alternating first faces  14  and second faces  16  of alternating concrete blocks  10  in adjacent ingots  24   a - 24   n , and successive cuts from the cutting assembly  28  cut along alternating first faces  14  and then second faces  16  of a same concrete block  10   a  within a single ingot  24   a.    
     In accordance with the foregoing, one technical effect is improved dual-face dual-split concrete products, both as to the concrete blocks themselves as well as to improved cutting techniques for same. 
     Accordingly, it should be readily apparent that this specification describes illustrative, exemplary, representative, and non-limiting embodiments of the inventive arrangements. Accordingly, the scope of the inventive arrangements are not limited to any of these embodiments. Rather, various details and features of the embodiments were disclosed as required. Thus, many changes and modifications as readily apparent to those skilled in these arts are within the scope of the inventive arrangements without departing from the spirit hereof, and the inventive arrangements are inclusive thereof. Accordingly, to apprise the public of the scope and spirit of the inventive arrangements, the following patent claims are made: