US20090000234A1

US20090000234A1 - Concrete blocks with non-geometric face surfaces

Info

Publication number: US20090000234A1
Application number: US11/768,664
Authority: US
Inventors: Timothy A. Bott; Robert A. Gravier
Original assignee: Allan Block Corp
Current assignee: Allan Block LLC
Priority date: 2007-06-26
Filing date: 2007-06-26
Publication date: 2009-01-01
Also published as: AU2008269002A1; WO2009002623A1; CA2664839A1; MX2009013895A; EP2171162A1

Abstract

Concrete blocks having face surfaces embossed with non-geometric patterns. The blocks may be of various sizes with some having faces surfaces with lengths and heights that are multiples other blocks. The blocks may have multiple sizes, colors or combinations of colors, face surface patterns, and set back configurations. Also, walls formed from such blocks and mold boxes usable in the formation of the blocks are included.

Description

BACKGROUND

Concrete blocks have been used to create a wide variety of mortared and mortarless walls. These walls have been used in applications ranging from retaining walls for sloped areas, building construction, sound barriers, and other landscaping and structural applications. While blocks have primarily been valued for their ability to meet structural requirements, the demand for more attractive block products and walls is increasing.

SUMMARY OF THE INVENTION

In one embodiment in accordance with the invention, a concrete block has a face surface that is convergent toward a generally horizontal edge with respect to a plane extending vertically through the block, the face surface having a non-geometric pattern molded thereon, the face surface being configured such that no first point on said face surface is spaced further from said plane than any other point on said face surface positioned in a vertical line further from the generally horizontal edge than said first point.
Another embodiment in accordance with the invention includes a mold box for forming concrete blocks in a high speed block machine. The mold box has an open top and bottom, opposed longitudinal side panels and opposed lateral end panels. There is a reciprocating shoe for reciprocatory up and down motion to engage a raw concrete mix within the mold box so as to configure a surface of the blocks as they are oriented within the mold box. A non-geometric pattern is embossed on at least one surface of the mold box, the surface being tapered so as to allow the block formed within the mold to disengage from the mold box.
In another embodiment in accordance with the invention, a method for the manufacture of concrete blocks having non-geometric patterns on their face surfaces is disclosed. The method includes providing a mold box having an open top and bottom, opposed longitudinal side panels and opposed lateral side panels. The mold box has a reciprocating top shoe for reciprocatory up and down motion to engage a raw concrete mix within the mold box so as to configure a surface of the blocks as they are oriented within the mold box and a divider plate for separating individual blocks within the mold box. The divider plate has opposed, outward facing surfaces that are downwardly convergent with respect to a vertical plane passing through the divider plate. Each convergent surface has a non-geometric pattern embossed thereon and each convergent surface is configured such that no first point on said surface is spaced further from said plane than any other point on said surface positioned directly vertically above said first point. The method further involves charging concrete into the open top of the mold box, and forcing the concrete into intimate contact with the convergent surfaces of the divider plate to form a molded block unit comprising two or more blocks. The mold box and divider plate are then vertically separated from the molded block unit with the block unit being spaced beneath the mold box and divider plate.
In another embodiment in accordance with the invention, a wall constructed of concrete blocks having various sizes and various patterns formed on their face surfaces includes a plurality of individual blocks stacked in an array of superimposed rows, with each block having at least one molded face surface with a non-geometric pattern formed thereon. The wall includes a first block having a first face surface with a length that is a multiple of an integer greater than one of the length of a second face of a second block. The wall also has a third block having a third face surface with a height that is a multiple of an integer greater than one of the height of a fourth face of a fourth block. The wall has blocks of various sizes and various face surface patterns distributed throughout the wall to create a non-uniform appearance.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a block in accordance with embodiments of the invention.

FIG. 2 is a cross section views of the block shown in FIG. 1 taken from the perspective indicated at “A.”

FIG. 3 is a cross section views of the block shown in FIG. 1 taken from the perspective indicated at “B.”

FIG. 4 is a cross section views of the block shown in FIG. 1 taken from the perspective indicated at “C.”

FIG. 5 is a perspective view of a block in accordance with embodiments of the invention and a corresponding mold surface.

FIG. 6 is a perspective view of a division plate in accordance with embodiments of the invention.

FIG. 7 is a perspective view of the other side of the division plate of FIG. 6.

FIG. 8 is a perspective view of a mold box in accordance with embodiments of the invention and a set of blocks that could be formed therein.

FIG. 9 is a cross section of the mold box of FIG. 8 as a set of blocks is being formed.

FIG. 10 is a perspective view of a mold box in accordance with embodiments of the invention and blocks formed from the mold box.

FIG. 11 shows an example of a concrete blocks in accordance with embodiments of the invention.

FIG. 12 shows an example of a concrete blocks in accordance with embodiments of the invention.

FIG. 13 shows an example of a concrete blocks in accordance with embodiments of the invention.

FIG. 14 shows an example of a concrete blocks in accordance with embodiments of the invention.

FIG. 15 shows an example of a concrete blocks in accordance with embodiments of the invention.

FIG. 16 shows an example of a concrete blocks in accordance with embodiments of the invention.

FIG. 17 is an elevation view of a collection of blocks in accordance with embodiments of the invention.

FIG. 18 is an elevation view of a wall in accordance with embodiments of the invention.

FIG. 19 is an elevation view of a wall in accordance with embodiments of the invention.

DETAILED DESCRIPTION

Concrete blocks in accordance with the invention may be used in many applications including but not limited to retaining walls, sound barriers, landscaping walls, etc. The blocks and molds described herein allow for the construction of unique and attractive wall structures usable in a variety of applications. The ability to combine blocks of various sizes, colors, and surface patterns to create walls with desirable aesthetic features is but one advantage associated with this disclosure.
FIG. 1 is a perspective view of a block in accordance with embodiments of the invention. FIGS. 2, 3, and 4 are cross section views of the block shown in FIG. 1, the cross sections views taken from the perspectives indicated at “A,” “B,” and “C,” respectively. The block 50 is generally rectangular in shape and has bottom 60, top 70, rear 80, two sides 90 and front 100. The bottom 60 and rear 80 surfaces of this embodiment are generally planar and arranged generally normal to one another. The sides 90 may be in normal arrangement to the front surface 100 when viewed from above or one or both may be angularly arranged thereto to allow for the construction of curved retaining walls. In the embodiment shown, the side walls 90 are angled but the rear wall 80 extends beyond the intersection with the side walls 90 so that the rear wall is essentially the same length as the front face 100. The portions of the rear wall 80 that extends beyond the intersection of the rear wall 80 with the side walls 90 could be removed to allow for the construction of curved portions of retaining wall.
The top 70 includes a first support area 1 10 defined over a predetermined area of the top for the support of additional blocks and a vertically extending shoulder 120 adjacent the front surface of the block. The embodiment includes a second top surface 130 at the uppermost end of the extending shoulder. When used to construct walls, the support area 110 and the vertical shoulder 120 provide a locating surface to receive an additional vertically positioned block on top of the block 50. The additional block may be positioned rearwardly from the front surface 100 of the receiving and supporting block whereby a wall of tiers of such blocks may extend rearwardly and upwardly from a support surface 110.
Block 50 includes a front surface 100 that includes a rearwardly and upwardly directed face surface 10 and a lower generally vertical portion 140 generally normal to the bottom surface 60. The lower vertical portion 140 may be configured to interact with the vertical shoulder 120 of an additional block onto which the block is placed. In an alternative embodiment, there is no separate lower generally vertical portion and the face surface 10 of the block extends all of the way to the bottom surface 60 of the block 50. In another alternative embodiment, the face surface 100 could be rearwardly and downwardly directed so that the upper portion of the face surface 100 extended beyond the lower portion.
The front surface 100 of block 50 includes a face surface 10 that has a non-geometric pattern 20 molded thereon. As can best be seen in FIGS. 2-4, the block 50 has a face surface 10 that is convergent toward a generally horizontal edge 15 with respect to a plane V extending vertically through the block. The face surface 10 is configured such that no first point 30 on the face surface is spaced further from said plane than any other point 40 on said face surface 100 positioned in a vertical line further from the generally horizontal edge 15 than said first point 30. In this particular embodiment the face surface 100 converges upwardly, so no first point 30 on the face surface is spaced further from said plane than any other point 40 on said face surface positioned directly below said first point 30. Each vertical segment of the face surface 100 of the embodiment in FIG. 1 is upwardly convergent so that the block may be formed in a high speed block machine and disengage from the mold box without significantly degrading the non-geometric pattern 20 on the face surface. Blocks could also be formed “upside down” in a high speed block machine so that the block as installed would have a face surface that is downwardly convergent with respect to a vertical plane. As can be seen from the exemplary face surface in FIG. 1, an intricate non-geometric pattern can be formed while keeping each vertical segment upwardly convergent as shown in FIGS. 2-4.
A non-geometric pattern may be contrasted with a geometric pattern, which uses simple geometric forms like circles and squares. Such non-geometric patterns may include, but are not limited to, patterns resembling worn or hewn natural stone, patterns resembling layered or sedimentary stone, patterns resembling rugged stone, and others that are all contemplated within the scope of this disclosure.
Blocks such as those shown in FIG. 1 may be made of concrete that is a variegated mixture of concrete that is dyed or otherwise different in color. In other words, a non-homogeneous mixture of concrete of different colors may be injected into a mold to form blocks of essentially random colors and combinations of colors. The veining or dappling effect of the various colors of the concrete creates more interesting looking blocks. The walls formed from these collections of blocks, particularly if the collection contains blocks of various sizes, colors and color combinations, and face surface patterns, are more attractive and appealing in many applications than walls constructed of more uniform blocks.
FIG. 5 is a perspective view of a block in accordance with embodiments of the invention and a corresponding mold surface. The block 50 has a face surface 10 with a non-geometric pattern 20 molded thereon. The corresponding mold surface 155 is embossed with a non-geometric pattern 20 that is transferred to the block 50 during the block production process. The mold surface 155 of the embodiment shown in FIG. 5 is a division plate 150 configured for installation in a mold box. The division plate is tapered at an angle T so that it is narrower at the bottom than the top. The mold surface 155 is configured such that each point on the mold surface is spaced farther from a vertical plane than any other point directly below the first point. As the block 50 is disengaged from the mold surface 155 by moving down relative to the mold surface 155, the block disengages from the mold surface without direct interference by the surface 155.
FIG. 6 is a perspective view of a division plate in accordance with embodiments of the invention. FIG. 7 is a perspective view of the other side of the division plate of FIG. 6. The division plate 150 has a non-geometric pattern 20 embossed thereon. The non-geometric pattern 20 on each side of the division plate is different, allowing for the production of two blocks with different non-geometric patterns at the same time. The division plate 150 is thicker at the top than at the bottom as described above, and the face surfaces of the division plate 150 are configured such that each point on the mold surface is spaced farther from a vertical plane than any other point directly below it. It may be advantageous to consider issues like plate thickness while designing the different non-geometric patterns on each side of the plate to ensure that the plate does not become too thin at a point where each face patter recedes.
FIG. 8 is a perspective view of a mold box in accordance with embodiments of the invention and a set of blocks that could be formed therein. The mold box of FIG. 8 may be used for forming concrete blocks in a high speed block machine. The mold box 175 has an open top and bottom. The box 175 has opposed longitudinal side panels 160 and opposed lateral end panels 170. A reciprocating shoe 180 may engage a raw concrete mix within the mold box 175 so as to configure the top surface of the blocks as they are oriented within the mold box. This “top surface” may in fact be the a bottom or other surface as the blocks are ultimately oriented, and the reference to top only applies to the block as oriented within the mold box. The same applies to references to bottom and side surfaces. The mold box also includes a moveable planar base support 210 that acts as the bottom of the mold box to form blocks 50.
The longitudinal side panels 160 of the embodiment of FIG. 8 have optional core bar receiving openings 165 formed therein and an optional core bar 200 that may be reciprocally introduced and removed from the mold box 175 to configure a bottom surface of the blocks 50 as they are oriented in the mold box. For example blocks 50 may have a lower generally vertical portion 140 formed on the front surface. As the mold box 175 is filled with raw concrete, the core bar 200 is positioned within the mold box 175. The core bare 200 is then removed from the mold box 175 through the core bar opening 165. The blocks are then allowed to exit the mold box 175 through the bottom of the mold box.
In some embodiments in accordance with the invention, core bars 200 of various sizes may be used to create blocks 50 having different set backs for the generally vertical portion 140. When these blocks are used to form a wall, the various set backs for the generally vertical portion 140 provide varied set-backs for individual blocks when the generally vertical portion 140 interacts with the vertical shoulder 120 of a lower block to provide a more interesting appearance to the wall. The core bar receiving openings 165 may be large enough to accommodate core bars 200 of various sizes so that blocks 50 having set backs for the generally vertical portion 140 of various depths may be formed using the same mold box 175, or different mold boxes 175 may be used with corresponding core bars 200.
A non-geometric pattern 20 is embossed on at least one surface of the mold box, the surface being tapered so as to allow the block formed within the mold box 175 to disengage from the bottom of the mold box. In the embodiment shown in FIG. 8, the surface of the mold box that is embossed with a non-geometric pattern 20 is a divider plate 150. Each side of the divider plate 150 may have a different non-geometric pattern embossed thereon so that the blocks 50 formed in the mold box will each have a different non-geometric pattern molded on it. In alternative embodiments of a mold box 175 in accordance with the invention, the longitudinal side panels 160 and/or the lateral end panels 170 may be embossed with a tapered non-geometric pattern 20 in addition to or instead of the divider plate 150.
In this embodiment the edges 190 of the shoe 180 adjacent to the surface of the mold box that is embossed with a non-geometric pattern is shaped to coincide with the upper edge of the surface of the mold box that is embossed, in this case the divider plate 150. Because the top of the embossed edge may be somewhat irregular, the shoe may be configured with an irregular surface to better form the top surface (as oriented in the mold box) of the block 50 and then assist in the removal of the formed blocks from the mold.
FIG. 9 is a cross section of the mold box of FIG. 8 as a set of blocks is being formed. Each block 50 is formed between the shoe 180, the planar base support 210, the divider plate 150, the longitudinal side panels 160 (not shown), and opposed lateral end panels 170. The optional core bar 200 forms a generally vertical portion 140 on the front face of the block. Once the blocks are formed, the core bar 200 is removed and the moveable planar base support 210 is lowered relative to the other elements of the mold box so that the blocks 50 slide out of the mold box. The divider plate 150 is embossed with a non-geometric pattern, and each point on the divider plate 150 is closer to the center of the divider plate 150 than any point above that point so that the blocks 50 may slide out of the bottom of the mold box without being marred by the embossed surface.
FIG. 10 is a perspective view of a mold box in accordance with embodiments of the invention and blocks formed from the mold box. A mold box 175 for forming concrete blocks 50 in a high speed block machine has an open top and bottom, opposed lateral side panels 160 and opposed longitudinal side panels 170. The assembly also includes a reciprocating top shoe 180 for reciprocatory up and down motion to engage a raw concrete mix so as to configure the top surface of the blocks 50 as they are oriented within the mold box. The assembly may also include a moveable planar base support 210 that acts as the bottom of the mold box as it is filled with concrete mix. The mold box may also include one or more divider plates 150 for separating blocks units within the mold box. The divider plate 150 may have a non-geometric pattern 20 embossed on it that will impress or emboss a non-geometric pattern 20 on the face surface 10 of the block 50. In some embodiments each side of the divider plate 150 has a different non-geometric pattern 20 embossed on it, providing the blocks 50 with a wider variety of face surface 10 appearances.
The divider plate 150 is generally thicker at the top than at the bottom. This allows the formed block 50 to be removed from the bottom of the mold without the divider plate 150 marring the face surface 10 of the block. Even though the divider plate 150 is generally thicker at the top, a non-geometric pattern 20 may be embossed on the divider plate that has various contours and ridges. This can be accomplished by ensuring that each vertical segment of the divider plate 150 is always getting thicker as you move from the bottom to the top of the divider plate 150. In other words, if one were to segment the divider plate 150 into multiple vertically divided segments, each segment would generally get thicker as you move to the top of the divider plate, although different segments would get thicker at different points between the top and bottom of the divider plate 150. Each first point on the divider plate 150 is closer to the vertical center of the divider plate 150 than any point directly above that first point. In some embodiments, the non-geometric pattern 20 formed on the face surface 10 may resemble a naturally occurring stone.
In the embodiment shown in FIG. 10, inside surfaces of the longitudinal side panels 160 and lateral side panels 170 are also embossed with a non-geometric pattern 20. These side panels are also generally tapered to allow the block formed therein to be removed through the bottom of the mold and to disengage readily from the side panel without disturbing the pattern 10 embossed on the block 50. This embodiment also includes two divider plates 150, each with two sides that are embossed with a non-geometric pattern 20. All of these embossed surfaces may be embossed with different non-geometric patterns to provide a wide variety of face surfaces 10 to the blocks 50, all of which enhance the aesthetic appeal of walls constructed from such blocks.
FIGS. 11-16 show examples of other concrete blocks in accordance with embodiments of the invention. These blocks all have face surfaces with non-geometric patterns 20 formed thereon. Each of the generally vertical face surfaces 10 are tapered so that they converge toward a generally horizontal edge 15 with respect to a plane extending vertically through the block, the plane oriented parallel to the horizontal edge 15 edge of the face surface and behind the face surface. Each point on the generally vertical face surface 10 is spaced further from said plane than any other point on said face surface positioned in a vertical line further from the generally horizontal edge 15 than said first point. It should be noted that the horizontal edge on the blocks in FIGS. 14 and 16 is the bottom edge of the block and the face surfaces 10 of these blocks converge downwardly toward a vertical plane located behind the face surface 10 while the blocks of FIGS. 11-13 and 15 converge upwardly in that sense.
The block of FIG. 11 is a freestanding landscape block. This embodiment has parallel load bearing surfaces 220, first and second ends 230, and first and second opposed face surfaces 10. The ends of this block are transverse to the load bearing surfaces 220 and the opposed face surfaces 10. The load bearing surfaces of the block have mating interlocks 240 comprising arcuate cores and protruding arcuate interlocks receivable in the cores. The interlocking cores are not vertically aligned with the protruding interlocks on the same building block. The block may be configured so that each end of a block comprises a half interlock and adjacent ends of a pair of blocks in a row together define an interlock portion that interlocks with a mating full interlock portion carried by a block in a vertically adjacent row of blocks. Blocks of this type are described more fully in U.S. Pat. No. 6,948,282, entitled “Interlocking Building Block,” the relevant portions of which are hereby incorporate by reference.
The block of FIG. 12 is a freestanding landscape block usable as an end block in conjunction with the block of FIG. 11. This block has parallel load bearing surfaces 220, an end 230, and first and second opposed face surfaces 10, and a third face surface 10 opposite end 230. The end of this block are comprises a half interlock 240 that interacts with an adjacent end of a block in a row to define an interlock portion that interlocks with a mating full interlock portion carried by a block in a vertically adjacent row of blocks. Blocks of this type are described more fully in U.S. Pat. No. 6,948,282, the relevant portions of which are hereby incorporate by reference.
The block of FIG. 13 is a cap block for use with blocks such as the block of FIG. 1. This block has a top face portion 35 with a non-geometric pattern 25 molded thereon. The top face 15 is formed by a reciprocating shoe so there are no limitations as to how the non-geometric pattern 25 is configured because the shoe lowers to mold the top face and raises away vertically to disengage the block. The front face 10 has a non-geometric pattern 20 molded thereon. This non-geometric pattern may be formed by a vertical mold surface and is configured such that each point of the face surface is closer to the rear wall 80 than any point directly below that point on the face surface 10. The block has a front wall 100 that includes the face surface 10 and a lower generally vertical portion 140. The lower vertical portion 140 may be configured to interact with the vertical shoulder 120 of an additional block 50 (FIG. 1) onto which the block is placed. In an alternative embodiment, there is no separate lower generally vertical portion and the face surface 10 of the block extends all of the way to the bottom surface of the block.
The block of FIG. 14 is a block for use in creating structural walls without mortar. The block has opposed face surface 10 with a non-geometric pattern molded thereon. The generally horizontal surface 280 resembles a truncated cone when viewed from the end 300. The generally horizontal surface 260 is configured to interact with the surface 280 of an adjacent block by being angle inwardly so that the angled surface 250 will engage the angled surface 280 to form a stable wall of blocks. End 300 is recessed relative to the face surfaces 10 and end 310 extends beyond the face surfaces 10 so that adjacent blocks in a row of blocks interact end-to-end to increase wall stability. Blocks of this type are described more fully in U.S. Pat. No. 6,082,067 entitled “Dry Stackable Block Structures,” the relevant portions of which are hereby incorporated by reference.
The block of FIG. 15 is a retaining wall block that uses a pin and grove design to assist in stabilizing the wall. The block of FIG. 15 has a face surface 10 with a non-geometric pattern 20 as described above. The side walls 320 taper rearwardly such that the rear wall 330 is shorter than the face surface 10. There are grooves 350 and passages 340 located within the grooves 350. The passages 340 pass completely through the block and allow for the installation of pins through the blocks to aid in the stabilization of a wall constructed from the blocks. Blocks of this type are described more fully in U.S. Patent Application Pub. No. US 2006/0117697, entitled “Modular Block System,” the relevant portions of which are hereby incorporated by reference.
The block of FIG. 16 is a traditional concrete building block used on construction of concrete walls. This block is usable in mortared applications. The basic block is well known in the art, but the embodiment of FIG. 16 has a non-geometric pattern 20 molded thereon that may be formed by a vertical mold surface and is configured such that each point of the face surface is closer to the longitudinal center line of the block than is any point directly above that point on the face surface 10. This embodiment of this block is formed upside down in a high speed block making machine. A block formed right side up would have a face surface 10 configured such that each point of the face surface is closer to the longitudinal center line of the block than is any point directly below that point on the face surface 10.
FIG. 17 is an elevation view of a collection of blocks in accordance with embodiments of the invention. The face surface 10 of each block is shown. The face surface10 is a surface that will be visible when the block is installed in a wall. Other surfaces of the block may also be visible, but it is the face surface that is the predominant feature of the block once it is installed in a wall. Some blocks will have only one face surface, as in the main load bearing blocks of a retaining wall. Other blocks will have two or more face surfaces. A wall with two visible sides will be primarily constructed from blocks that have two face surfaces on opposite sides of the block. A block used at the end or top of a wall may have even more face surfaces, as will a block used to make a corner in the wall.
In FIG. 17, four sizes of blocks are generally indicated at “W,”, “X,” “Y.” and “Z.” The length of the face surfaces 10 of the blocks in each group is indicated by LA where A is the letter associated with the group. For example, L_Wis the length of the face surface 10 of the blocks in group W. Similarly, the height of the face surfaces 10 of the block in each group is indicated by H_A, where A is the letter associated with the group. The height of the face surfaces of blocks of group Y is H_Y.
In the exemplary collection of blocks of FIG. 17 L_Wis an integer multiple greater than 1 of L_Yand L_Z. In this example, the integer is 2, meaning that the face surface 10 of the blocks W is twice as long as the face surface 10 of blocks Y and Z. L_Yin this embodiment equals L_Aand is therefore also two times L_Xand L_Z. In other embodiments the integer could be 3 or greater. Also, in the collection of FIG. 17, H_Wequals H_Xand the face surfaces of the W and X blocks are twice the height of the face surfaces 10 of the Y and Z blocks.
The fact that the lengths and heights of the blocks in the collection are equal to each other or integer multiples greater than one of each other allows walls to be constructed with blocks of various sizes arranged in a variety of patterns because, for example, two blocks that are twice as long as a single other block of the collection, or three that are three times as long, may be used in lieu of a single block, and need not necessarily be adjacent to each other. If properly arranged, eventually the combination of blocks that are integer multiples of each other in height and length of face surface can form a uniform wall with a unique appearance.
Blocks such as those shown in the collection of FIG. 17 may also have a non-geometric pattern 20 molded thereon. In some embodiments in accordance with the invention, this pattern 20 is formed by embossed elements of a mold box usable in a high speed block making machine. A collection of blocks may include several different patterns 20 on each block. Thus the variety of patterns and block sizes may combine to create an even more visually interesting wall design.
FIG. 18 is an elevation view of a wall in accordance with embodiments of the invention. The wall of FIG. 18 combines the elements of various non-geometric patterns, block sizes, and block colors to create a visually pleasing non-manufactured looking concrete wall. In the case of retaining walls as discussed earlier, the wall could also use various setback depths, to provide even more interest. The wall of FIG. 18 could be constructed of blocks such as those described herein or any blocks known in the art that are amenable to the techniques taught and claimed in this application.
FIG. 18 demonstrates how a collection of blocks in accordance with the invention can be arranged to form a wall having interesting appeal with only four sizes of face surfaces 10 and a limited number of non-geometric patterns. Because the height and length of the face surfaces 10 of the blocks are either equal to the dimensions of adjacent blocks or multiples of integers greater than one of the length and/or the width of adjacent blocks, the collection of blocks can be used to create a pseudorandom looking wall while easily consuming a collection of blocks such as that in FIG. 17. The resultant wall can be built to a variety of heights and can be used in a wide variety of applications.
FIG. 19 is an elevation view of a wall in accordance with embodiments of the invention. The wall of FIG. 19 only includes one size of blocks, but still shows the interesting and appealing looks that can be achieved using a collection of blocks with non-geometric face patterns in accordance with the invention. Other arrangements of blocks of various sizes are contemplated by the inventors and will occur to those or ordinary skill upon reading this disclosure.
It will be appreciated that various modifications may be made to the techniques of the present invention; it being further understood that the examples given herein are for purposes of illustration only and are not to be construed as a limitation upon the scope to which the invention is otherwise entitled.

Claims

1. A concrete block comprising a face surface that is convergent toward a generally horizontal edge with respect to a plane extending vertically through the block, the face surface having a non-geometric pattern molded thereon, the face surface being configured such that no first point on said face surface is spaced further from said plane than any other point on said face surface positioned in a vertical line further from the generally horizontal edge than said first point.

2. The concrete block of claim 1, wherein the block is a retaining wall block.

3. The concrete block of claim 2, wherein the block has a first load bearing surface, a second load bearing surface, and, rear, side and front surfaces, said first load bearing and rear surfaces being generally planar and arranged generally normal to one another, said second load bearing surface including a support area defined over a predetermined area for the support of additional blocks, a vertically extending shoulder adjacent said front surface of said block and a surface at the end of said extending shoulder parallel to the second load bearing surface, said support area and said vertical shoulder providing a locating surface to receive an additional vertically positioned block thereon wherein the additional block may be positioned rearwardly from the front surface of the receiving and supporting block whereby a wall of tiers of such blocks may extend rearwardly and upwardly from a support surface.

4. The concrete block of claim 3, said front surface further including a generally vertical portion generally normal to said first load bearing surface, said vertical portion configured to interact with the vertical shoulder of an additional block onto which the block is placed.

5. The concrete block of claim 2, the block having first and second load bearing surfaces, rear, side and front surfaces, the side surfaces tapering rearwardly such that the rear surface is shorter than the front surface, the first load bearing surface having grooves defined thereon, the block having passages beginning within the grooves that pass completely through the block and allow for the installation of pins through the blocks to aid in the stabilization of a wall constructed from a plurality of the blocks.

6. The concrete block of claim 1, wherein the block is a freestanding mortarless wall block.

7. The concrete block of claim 6, wherein the block has opposed front and rear face surfaces opposed ends, a first generally horizontal surface resembling a truncated cone when viewed from an end, a second generally horizontal surface configured to interact with the first horizontal surface of a lower block by being angled inwardly and upwardly so that the inwardly angled second generally horizontal surface of a block surface will interact with the angled first generally horizontal surface of a vertically stacked adjacent block to form a stable wall of blocks.

8. The concrete block of claim 7, wherein one end is recessed relative to the face surfaces and the other end extends beyond the face surfaces so that adjacent blocks in a row of blocks interact end-to-end to increase wall stability.

9. The concrete block of claim 6, the block having first and second parallel load bearing surfaces, first and second ends, and first and second opposed face surfaces, the ends being transverse to the load bearing surfaces and the opposed face surfaces, the load bearing surfaces of the block having mating interlocks comprising arcuate cores and protruding arcuate interlocks receivable in the cores, wherein the interlocking cores are not vertically aligned with the protruding interlocks on the same building block, the block being configured so that each end of a block comprises a half interlock and adjacent ends of a pair of blocks in a row together define an interlock portion that interlocks with a mating full interlock portion carried by a block in an adjacent row of blocks.

10. The block of claim 9, wherein each of the first and second opposed face surfaces has a different non-geometric pattern molded thereon.

11. A mold box for forming concrete blocks in a high speed block machine, the mold box having an open top and bottom, opposed longitudinal side panels and opposed lateral end panels;

a reciprocating shoe for reciprocatory up and down motion to engage a raw concrete mix within the mold box so as to configure a surface of the blocks as they are oriented within the mold box; and

a non-geometric pattern embossed on at least one surface of the mold box, the surface being tapered so as to allow the block formed within the mold to disengage from the mold box.

12. The mold box of claim 11, further comprising a divider plate for separating blocks units within the mold box, the divider plate having opposed, outward facing surfaces that are downwardly convergent with respect to a vertical plane passing through the divider plate, each convergent surface having a non-geometric pattern embossed thereon and each convergent surface being configured such that no first point on said surface is spaced further from said plane than any other point on said surface positioned directly vertically above said first point.

13. The mold box of claim 12, wherein one convergent surface of the divider plate has a non-geometric pattern embossed thereon that is different from the non-geometric pattern embossed on the other convergent surface.

14. The mold box of claim 11, further comprising a movable planar base support arranged to travel along a generally horizontal axis of motion and to support said mold box.

15. The mold box of claim 11, wherein the lateral side panels have core bar receiving openings formed therein and a core bar that may be reciprocally introduced and removed from the mold box to configure a bottom surface of the blocks as they are oriented in the mold box.

16. The mold box of claim 15, further comprising core bars of various sizes, wherein the core bar receiving openings are large enough to accommodate core bars of various sizes so that blocks having grooves of various sizes may be formed using the same mold box.

17. The mold box of claim 14, wherein the support is a conveyor belt.

18. The mold box of claim 12, wherein the inside surfaces of the lateral side panels and/or the longitudinal walls are embossed with a non-geometric pattern.

19. The mold box of claim 12, further comprising a second divider plate, wherein each side of each divider plate has a different non-geometric pattern embossed thereon.

20. The mold box of claim 18, wherein each non-geometric pattern embossed on the divider plate is different from each non-geometric pattern embossed on the longitudinal side panels and/or the lateral walls, and each non-geometric pattern embossed on the longitudinal side panels and/or the lateral side panels is different from each other.

21. A method for the manufacture of concrete blocks having non-geometric patterns on their face surfaces comprising:

providing a mold box having an open top and bottom, opposed longitudinal side panels and opposed lateral side panels; a reciprocating top shoe for reciprocatory up and down motion to engage a raw concrete mix within the mold box so as to configure a surface of the blocks as they are oriented within the mold box; and a divider plate for separating individual blocks within the mold box, the divider plate having opposed, outward facing surfaces that are downwardly convergent with respect to a vertical plane passing through the divider plate, each convergent surface having a non-geometric pattern embossed thereon and each convergent surface being configured such that no first point on said surface is spaced further from said plane than any other point on said surface positioned directly vertically above said first point

charging concrete into the open top of the mold box, and forcing the concrete into intimate contact with the convergent surfaces of the divider plate to form a molded block unit comprising two or more blocks,

vertically separating the mold box and divider plate from the molded block unit with the block unit being spaced beneath the mold box and divider plate.

22. The method of claim 21, wherein one or more of the longitudinal side panels and/or the lateral side panels has a non-geometric pattern embossed thereon.

23. A wall constructed of concrete blocks having various sizes and various patterns formed on their face surfaces comprising:

a plurality of individual blocks stacked in an array of superimposed rows, with each block having at least one molded face surface with a non-geometric pattern formed thereon;

at least a first block of the plurality of blocks having a first face surface with a length that is a multiple of an integer greater than one of the length of a second face of a second block; and

at least a third block having a third face surface with a height that is a multiple of an integer greater than one of the height of a fourth face of a fourth block, wherein blocks of various sizes and various face surface patterns are distributed throughout the wall to create a non-uniform appearance.

24. The wall of claim 23, wherein the wall is a mortarless retaining wall and each block has a vertically extending shoulder adjacent said face surface of said block and extending entirely therealong to provide a continuous block positioning member in close association to said face surface wherein an additional block is positioned rearwardly from the face surface of a receiving and supporting block whereby a wall of tiers of such blocks extend rearwardly and upwardly from a support surface.