Patent ID: 8110134

Claim:
A method for manufacturing dobies, the method comprising the steps of: (a) placing a first dobie tray in a first box; (b) filling a plurality of cavities in the first dobie tray with a cementitious material; (c) placing a second dobie tray identical to the first dobie tray in the first box on top of the first dobie tray, wherein the second dobie tray is oriented in a position that is rotated in respect to the first dobie tray so that the first dobie tray provides support to the second dobie tray; (d) filling a plurality of cavities of the second dobie tray with cementitious material; (e) sealing the first box; and (f) allowing the cementitious material in the plurality of cavities in the first dobie tray and in the plurality of cavities in the second dobie tray within the first box to cure; wherein said placing further comprises: forming a seal between each edge of the first dobie tray with a corresponding side of the first box; and forming a seal between each edge of the second dobie tray with a corresponding side of the first box; wherein the seals substantially prevent the cementitious material from running from the second dobie tray into the first dobie tray, and from running from the first dobie tray into a bottom of the first box; wherein each edge of the first and second dobie trays has a vertical rise and a sloping portion that slopes downward from the vertical rise towards a top surface of the first and second dobie trays; wherein any of the cementitious material that is sprayed on an interior walls of the first box will run down and be deflected by the sloping portion of the each edge into the plurality of cavities of the first and second dobie trays.