Abstract:
A block splitting tool having a splitting blade that is formed by edges of a plurality of smaller splitter segments. The splitter segments are arranged in a side-by-side relation such that the edges form a substantially continuous blade that is generally corrugated or jagged. The splitter segments may be operatively connected to a suitable support that, in turn, is attached to a block splitting machine. When the splitting blade of the tool engages and splits a block, the edges of the splitter segments form a plurality of fracture zones that are angled with respect to each other, which results in roughened facings on the newly cleaved smaller blocks. In a preferred embodiment, the splitter segments are removably attached to a support plate, so that they may be repositioned, replaced, and/or repaired.

Description:
FIELD OF THE INVENTION 
     The present invention generally relates to masonry blocks. More particularly, the present invention relates to tool for creating roughened facings on retaining wall blocks when the blocks are being cleaved or split. 
     BACKGROUND OF INVENTION 
     The manufacture of masonry blocks has been known for many years. Originally produced by casting individual blocks in single molds, advances in technology have led to production techniques that are able to produce multiple blocks not only from a mold matrix, but also from a single mold in which individual blocks are formed by splitting the molded block along a predetermined plane or planes, as the case may be. Production of multiple blocks from a single mold is preferred because the mold itself is simpler to design and build, fewer parts are required, and the blocks so produced are symmetrical, which facilitates later assembly into structures. Moreover, the blocks so produced have aesthetically pleasing split facings that are evocative of quarrying techniques and old world craftsmanship. 
     Sometimes, the aforementioned blocks are further processed by mechanically working the facings of the blocks so that they appear weathered and old. This can be achieved by tumbling, by mechanical working with flails or hammermills, or by providing additional hand dressing, for example. As one may imagine, such steps add to the total production time and expense. Moreover, additional machinery and training is usually required, which is usually factored into the cost of the finished product. 
     Thus, there is a need for tool that is able to produce a masonry block with a “weathered” facing. There is also a need for a tool that reduces the number of steps that are used to produce weathered facings on masonry blocks. There is yet a need for a block splitting tool that is easy to manufacture, assemble, repair, and reconfigure. 
     SUMMARY OF THE INVENTION 
     This invention is directed to a tool for splitting a large block of material into a plurality of smaller blocks having predetermined dimensions. A preferred embodiment of the tool comprises a plurality of splitter segments, each having a material working or splitting edge. The splitter segments are affixed to a suitable support so that their working edges form a generally continuous and corrugated splitting blade. With this embodiment, the splitter or splitting blade is able to form blocks that have roughened or weathered facings; however, it will be appreciated that other configurations are possible. 
     Another preferred embodiment of the tool comprises a plurality of removable and/or positionable splitter segments, each of which is provided with a material working edge. The splitter segments are attached to a suitable support and arranged so that the working edges of the splitter segments form a substantially continuous splitting blade. Preferably, the working edges of the splitter segments are positioned with respect to each other so that the resultant splitting blade is generally corrugated rather than linear. 
     The tool may be mounted on a movable crosshead of a conventional block splitter such that movement of the splitting blade is substantially perpendicular to a block to be split. A second tool having a second splitting blade may also be used, and it too may be mounted on a conventional, movable crosshead such that the second splitting blade is in opposing relation to the splitting blade of the first tool, and the motion of the crossheads define a working plane. Preferably, the first and second splitting blades are mirror images of each other, though this need not be necessarily so. 
     An object of the present invention is to provide a tool for splitting a larger block of material into a plurality of smaller blocks. 
     Another object of the invention is to simplify the process of producing weathered or roughened facings in masonry blocks. 
     Yet another object of the present invention is to reduce the number of parts needed to produce weathered facings in masonry blocks. 
     A feature of the present invention is that the tool comprises a plurality of smaller segments that are positioned together in a side-by-side and substantially continuous relation. 
     Another feature of the present invention is that the segments of the tool are removably positionable. 
     An advantage of the invention is that the tool may be easily reconfigured by repositioning the segments relative to each other. 
     Another advantage of the invention is that the tool may be used with existing machinery without modifications or adaptors. 
     These and other objects, features and advantages of the present invention will become apparent from the following detailed description thereof taken in conjunction with the accompanying drawings, wherein like reference numerals designate like elements throughout the several views. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a partial perspective view of a splitting station in which opposing splitting tools are used to split a block into smaller blocks; 
     FIG. 2 is a perspective view of the one of the splitting tools of FIG. 1; 
     FIG. 3 is a plan view of the splitting tool of FIG. 2; 
     FIG. 4 is a plan view of a second splitting tool in juxtaposition with the splitting tool of FIG. 3; 
     FIG. 5 is a perspective view of an alternative embodiment of a splitting tool; and, 
     FIG. 6 is a top plan view of the splitting tool of FIG.  5 .; 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 depicts a workstation  10  where a large block may be split into smaller blocks. Starting from the upper left, a symmetrically shaped, molded block A is positioned on a conveyer  12  that leads it to a point where the block is split into smaller blocks B, C by the splitting tools  14 ,  16  of the present invention. As shown, the splitting tools  14 ,  16  are positioned and arranged so that they engage a block from opposing directions. The splitting tools may be removably attached to crossheads  11 ,  13  of a splitter machine (not shown) for reciprocal motion towards and away from each other. It will be understood that the reciprocal motion of the splitting tools define a working or splitting plane  18  that is generally perpendicular to the block being split. As depicted at the bottom of the figure, block A has been split along an axis of symmetry  7 , which results in two similarly sized and shaped blocks B, C. It will be appreciated, however, that the block may be split along asymmetric axes to produce differently sized and shaped blocks. Such an asymmetric axis  9  is also shown in FIG.  1 . 
     One of the splitting tools  14  of FIG. 1 is depicted in greater detail in FIG.  2 . As shown, the splitting tool  14  comprises a support  20  upon which a plurality of splitter segments  22  are affixed. Each splitter segment  22  comprises a body having a root end  22   a  and a crown end  22   b,  with the root end being attached to the support, and the crown end terminating in a material working or splitting edge  24 . Each splitter segment  22  has a predetermined height, width, and thickness, and as shown the height and thickness of the splitter segments are substantially the same, while the widths are different. It will be appreciated, however, that the dimensions of the splitter elements may be varied without departing from the spirit and scope of the invention. 
     The splitter segments  22  are affixed to the support using known techniques and technologies, such as welding. The splitter segments may also be linked to each other at their sides, again using known techniques and technologies. However, it will be appreciated that the splitter segments need not be attached to each other at their sides in order for the splitting tool to operate effectively as a splitting blade, and there may even be small spaces between adjacent splitter segments. Generally, though, it is preferred that the splitter segments be in abutting contact with each other to form an uninterrupted splitting blade because it results in a stronger tool structure. As depicted, each splitter segment  22  is affixed to the support  20  such that its material working or splitting edge  24  extends therefrom in a substantially perpendicular relation to the support. The splitter segments are angled with respect to each other and with respect to the splitting plane to form a generally corrugated splitting blade generally indicated by reference numeral  26 , with the splitting blade having first and second ends  26   a  and  26   b.  The corrugated splitting blade  26  is able to produce a roughened or “weathered” facing because each edge  24  of each splitter segment creates its own localized fracture zone when it engages a block. 
     Referring to FIGS. 3 and 4, a pair of opposed splitting tools  14  and  16  are shown in juxtaposition, with the splitting blades of the opposing splitting tools being mirror images of each other. It will be appreciated that it is not necessary for the splitting blades to be mirror images of each other and it is envisioned, for example, that the opposing blades may have substantially different configurations. Moreover, it is also envisioned that the splitter segments  22  need not be planar and could be configured in other shapes such as arcs or angles, for example. Note that while the angles defined by the intersection of pairs of adjacent splitter segments are different, they could be more uniform without departing from the spirit and scope of the invention. It is preferred, however, that the angles be different from each other because it is believed that they facilitate the creation of a more roughened or weathered facing, and increase the randomness of the block facings. 
     As can be seen, the splitting blades  26  are oriented generally along the working plane  18  as defined by the motion of the crossheads  11 ,  13  (see, FIG.  1 ). Each splitting blade  26  has two ends  26   a  and  26   b,  each of which is optionally bifurcated into end segments  27   a,    28   a,  and  27   b,    28   b.  It will be understood that such bifurcations will produce a block that has rounded side facing edges, which create a more roughened or “weathered” look. In keeping with the goal of achieving a roughened or “weathered” look, it will be appreciated that the material working edges are arranged so that the edges are in a distinct angular orientation with respect to the working or splitting plane (see, FIGS.  3  and  4 ). This reduces the chance that the facings so produced will have what is perceived as a facet. The blade segments  22  are positioned along the splitting plane  18  and are preferably oriented so that substantially all of the blade segments intersect plane  18 . 
     A second embodiment of the present invention is depicted in FIGS. 5 and 6. While only one splitting tool  114  is depicted, it will be understood that the splitting process is better achieved by using a second oppositely disposed, splitting tool (see, FIGS.  1  and  3 ). Referring to FIG. 5, the splitting tool  114  as shown comprises a support or base mounted on a crosshead  113  (shown in dashed lines) and upon which a plurality of splitter segments  122  are attached, with each splitter segment  122  comprising a body having a root end  122   a  and a crown end  122   b,  and with the root end being attached to the support  120  and the crown end terminating in a material working or splitting edge  124 . Each splitter segment  122  has a predetermined height, width, and thickness, and as shown the height and thickness of the splitter segments are substantially the same, while the widths are different. It will be appreciated, however, that the dimensional characteristics of the splitter elements may be varied without departing from the spirit and scope of the invention. 
     The splitter segments  122  may be removably attached to the support  120  using known technologies and techniques. Preferably, L-shaped brackets  130  and threaded fasteners  132  such as cap screws are used to secure the splitter segments  122  to the support  120 . It will be appreciated that other forms of attachment may be used. For example, the splitter segments could be bolted directly to the support. This allows individual splitter segments to be attached, removed, rearranged, or repaired. As will be appreciated, the splitter segments need not contact each other at their sides in order for the splitting tool to operate effectively as a splitting blade, and there may even be small spaces between adjacent splitter segments  122 . Generally, though, it is preferred that the splitter segments be positioned so that their sides are in close proximity to, or in abutting contact with each other to form an uninterrupted splitting blade. As depicted, each splitter segment is affixed to the support such that its material working or splitting edge  124  extends therefrom in a substantially perpendicular relation, and the splitter segments  122  are angled with respect to each other, to form a splitting blade  126  having first and second ends  126   a  and  126   b.  Note that splitter segments are alternately angled with respect to each other and with respect to the splitting plane in a corrugated configuration. The splitting blade  126  is able to produce a roughened or “weathered” facing because each edge  124  of each splitter segment  122  creates its own localized fracture zone when it engages a block. 
     Referring to FIGS. 5 and 6, only one splitting tool is shown; however, it is understood that an additional, similarly configured, and arranged splitting tool could be used, as depicted in FIGS. 1,  3  and  4 . As with the embodiment as depicted in FIGS.  3  and  4 , it will be appreciated that it is not necessary for the splitting blades to be mirror images of each other and it is contemplated that the opposing blades may have substantially different configurations. Moreover, it is also envisioned that the splitter segments need not be planar and could be configured in other shapes such as arcs, for example. 
     As can be seen, the splitting blade  126  is oriented generally along the working plane  118  as defined by the motion of the crossheads (see, FIG.  1 ). The splitting blade  126  has two ends  126   a  and  126   b,  each of which is optionally bifurcated into end segments  127   a,    128   a,  and  127   b,    128   b.  It will be understood that such bifurcations will produce a block that has rounded side facing edges, which create a more roughened or “weathered” look. As shown most clearly in FIG. 6, the blade segments  122  may be oriented in a generally rounded or curved configuration in order to produce split blocks with curved front facings having a weathered or roughened look. 
     While preferred embodiments of the present invention have been shown and described, it should be understood that various changes, adaptations, and modifications may be made therein without departing from the spirit of the invention. Changes may be made in details, particularly in matters of shape, size, material, and arrangement of parts without exceeding the scope of the invention. Accordingly, the scope of the invention is as defined in the language of the appended claims.