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Patent 2060934 Summary

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(12) Patent: (11) CA 2060934
(54) English Title: HEATED STRIPPER SHOE ASSEMBLY
(54) French Title: SABOT DE DECOFFRAGE CHAUFFE
Status: Deemed expired
Bibliographic Data
(51) International Patent Classification (IPC):
  • B28B 7/42 (2006.01)
  • B28B 7/38 (2006.01)
(72) Inventors :
  • WOOLFORD, MICHAEL E. (United States of America)
(73) Owners :
  • BLOCK SYSTEMS INC. (United States of America)
(71) Applicants :
(74) Agent: CASSAN MACLEAN
(74) Associate agent:
(45) Issued: 1999-12-28
(22) Filed Date: 1992-02-10
(41) Open to Public Inspection: 1993-08-11
Examination requested: 1995-08-22
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data: None

Abstracts

English Abstract




The invention is a heated stripper shoe assembly for
use in manufacture of concrete masonry blocks. The heated
stripper shoe has a stripper shoe plate, at least one heat
block and at least one heat element fitted within the heat
block. Optionally, the stripper shoe assembly may also
comprise a heat shroud positioned over the heat block on the
upper surface of the stripper shoe plate, a standoff attached
to the heat shroud for affixing the assembly to a block
machine, and a mold for use with the stripper shoe assembly.
The invention also comprises methods of using the assembly.


Claims

Note: Claims are shown in the official language in which they were submitted.




THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A heated stripper shoe assembly comprising means for
forming structural features on composite masonry blocks, said
forming means comprising:
(a) a stripper shoe plate having a top side and
a bottom side, said stripper shoe plate bottom side comprising
at least one indentation;
(b) means for applying heat to selected areas
of the plate comprising a heating element
(c) means for affixing said heating element to
said stripper shoe plate comprising a heat block affixed to
said stripper shoe plate top side, said heat block being
positioned on said stripper shoe plate top side adjacent the
indentation in said plate bottom side, said block having a
containment portion adapted to receive said heating element,
and said heating element being positioned within said
containment portion; and
(d) means for releasably holding said heating
element in said containment portion.

2. The assembly of claim 1 wherein said heating means
comprises at least one heat element positioned on said stripper
shoe plate top side.

3. The assembly of claim 2 wherein said stripper shoe
bottom side comprises at least one indentation and said heat
element is attached to said stripper shoe top side adjacent
said indentation.

4. The assembly of claim 3 wherein said stripper shoe


-Page 1 of Claims-



comprises a plate having a top side and a bottom side and at
least four edges, and said stripper shoe indentation comprises
a depression running the length of at least one edge of the
shoe, and said heat element is positioned on the top side of
said shoe plate parallel to said indentation.

5. The assembly of claim 4 comprising fastening means,
said fastening means comprising a hollow rectangular block
having a top side and a bottom side.

6. The assembly of claim 5 wherein said block bottom
side is open and said heat element is in contact with said
stripper shoe top side.

7. The assembly of claim 4 wherein said heat element
comprises an electrical resistance element removably inserted
into said heat block.

8. The assembly of claim 1 additionally comprising a
heat shroud, said heat shroud positioned on said top surface
of said heated stripper shoe plate, said shroud having an
indentation for enclosing said heat block.

9. The assembly of claim 5 wherein said heat block
comprises a metal alloy.

10. The assembly of claim 9 wherein said heat block metal
alloy is selected from a group consisting of ASTM A36 steel,
ASTM 41-40 carbon steel, or mixtures thereof.

11. The assembly of claim 10 wherein said heat block
metal alloy comprises ASTM A36 steel.

12. The assembly of claim 8 wherein said heat shroud
comprises an alloy having a low thermal conductivity.

13. The assembly of claim 12 wherein said heat shroud

-Page 2 of Claims-



metal alloy is selected from the group consisting of copper,
brass, elemental aluminum, an aluminum oxide, an aluminum
alloy, or mixtures thereof.

14. The assembly of claim 13 wherein said heat shroud
comprises aluminum.

15. The assembly of claim 1 wherein said heated stripper
shoe additionally comprises a standoff, affixed to said heat
shroud.

16. A heated stripper shoe assembly for use in
manufacture of concrete masonry block, said heated stripper
shoe comprising:
(a) a stripper shoe plate comprising a lower side,
a top side and four edges, said stripper shoe plate having a
first and second indentations located adjacent and
substantially parallel to at least two edges on the plate;
(b) at least two heat blocks, said first heat block
positioned on said heated stripper shoe plate top side above
and parallel to said first indentation, said second heat block
positioned on said stripper shoe top side above and
substantially parallel to said second indentation;
(c) at least two heat elements, said first and
second heat elements each comprising a cylinder, said first
element removably inserted within said first heat block, and
said second element removably inserted into said second heater
element;
(d) a heat shroud positioned over said heat block
on the upper surface of said shoe plate, said heat shroud
comprising a lower side and an upper side, said heat shroud

-Page 3 of Claims-



lower side having at least two indentations for enclosing said
heat blocks; and
(e) means for attaching said heated stripper shoe
to a block machine, said attachment means comprising a standoff
attached to said heat shroud.

17. The assembly of claim 16 wherein said heat block
comprises a metal alloy selected from the group consisting of
ASTM A36 steel, ASTM 41-40 carbon steel, ASTM carbon steel, or
mixtures thereof.

18. The assembly of claim 16 wherein said heat element
comprises an electrical resistance element having a wattage
ranging from about 450 to about 1500 watts.

19. The assembly of claim 16 additionally comprising a
mold comprising four sides designed and positioned in a manner
to complement the outer perimeter of the stripper shoe plate,
said mold comprising an open bottom and open top.

20. The assembly of claim 19 wherein said heat elements
comprise electrical resistance elements having a wattage
ranging from about 450 to about 1500 watts.

21. The assembly of claim 19 wherein said heat shroud
comprises an aluminum alloy and said standoff comprises steel.

22. A method of using a shoe and mold assembly, said shoe
and mold assembly comprising:
(a) a stripper shoe plate comprising a lower side
and a top side;
(b) means for applying heat to a selected area of
the plate, said heating means affixed to the top side of the
plate over said area, wherein said area is above a bottom side


-Page 4 of Claims-



area shaped to apply detail to a block during molding; and
(c) a mold having an open top and a perimeter which
complements the outer perimeter of said stripper shoe plate,
said method comprising the steps of:
(i) filling said mold with composite
masonry fill: and
(ii) compressing said fill with said
activated heated stripper shoe plate.

23. The assembly of claim 1 wherein said containment
portion comprises a hollowed out portion in said heat block.

24. The assembly of claim 1 wherein said containment
portion has an open bottom.

25. The assembly of claim 24 wherein said hollowed out
portion runs generally parallel to the stripper shoe plate top
side and said heating element is in contact with said stripper
shoe plate top side.

26. The assembly of claim 23 wherein said heat block has
an open bottom and said heating element is in contact with said
stripper shoe plate top side.

27. The assembly of claim 23 wherein said heat block has
an open bottom, said heating element being in contact with said
stripper shoe plate top side, said heating element freely
transmitting heat from said containment area to the top side
of said stripper shoe plate.

28. A heated stripper shoe assembly for use in
manufacture of concrete masonry block, said heated stripper
shoe assembly comprising means for forming structural features
on composite masonry block, said forming means comprising:


-Page 5 of Claims-



(a) a stripper shoe plate comprising a lower
side, a top side and first, second, third and fourth edges,
said stripper shoe plate having first and second indentations
located adjacent and substantially parallel to respective first
and second edges on the plate wherein said first and second
edges on the plate wherein said first edge is parallel to said
second edge across the surface of said stripper shoe plate;
(b) at least two heat blocks, including a first
heat block and a second heat block, said first heat block
positioned on said stripper shoe plate top side parallel and
adjacent to said first indentation, said second heat block
positioned on said stripper shoe plate top side substantially
parallel and adjacent to said second indentation, said first
and second heat blocks each having a top side and bottom side,
said block bottom side having an opening, each of said blocks
having a containment portion; and
(c) at least two heating elements, including
a first heating element and a second heating element, said
first and second heating elements each comprising, a cylinder,
said first element removably inserted within said first heat
block containment portion, and said second element removably
inserted into said second heat block containment portion,
wherein each of said heat block bottom side openings allow free
transmission of heat to said stripper shoe plate top side while
insulating said stripper shoe assembly from heat generated by
each of said heating elements.

29. The assembly of claim 28 wherein said first and
second heat blocks each comprise a metal alloy selected from


-Page 6 of Claims-





the group consisting of ASTM A36 steel, ASTM 41-40 carbon
steel, and mixtures thereof.

30. The assembly of claim 28 wherein said first and
second heating elements each comprise an electrical resistance
element having a wattage ranging from about 400 to about 1500
watts.

31. The assembly of claim 28 additionally comprising a
mold comprising four sides designed and positioned in a manner
to complement the outer perimeter of the stripper shoe plate,
said mold comprising an open bottom and open top.

32. The assembly of claim 28 wherein said first and
second heating elements comprise electrical resistance elements
having a wattage ranging from about 450 to about 1500 watts.

33. The assembly of claim 28 wherein said first and
second heating elements are in contact with said stripper shoe
plate top side.

34. The assembly of claim 28 wherein said containment
area runs generally parallel to the stripper shoe plate top
side and said first and second heating elements are in contact
with said stripper shoe plate top side.

-Page 7 of Claims-

Description

Note: Descriptions are shown in the official language in which they were submitted.




20 609 3 4
Field of the Invention
The invention relates generally to stripper shoe/mold
assemblies for the manufacture of concrete masonry blocks.
More specifically, the invention relates to heated stripper
shoe/mold assemblies for the molding of concrete blocks
having edges or other detail or ornamentation of varying
size.
Background of the Invention
Various devices have been developed for the automatic
manufacture of concrete masonry blocks. For example, Bernham
et al, U.S. Patent No. 4,214,655, disclose a machine for the
automated casting, curing, moving and stacking of concrete
blocks. Jenkins, U.S. Patent No. 4,132,492, discloses a
self-propelled concrete screed machine having a winch and
cable propulsion system.
Whissell, U.S. Patent No. 4,802,836, discloses a
compaction device for concrete block molding. Pardo, U.S.
Patent No. 4,909,717 and counterpart UK Patent Application
No. 2,213,095A, discloses a concrete masonry casting
apparatus incorporating reciprocal actuating plungers which
cause a shape modification of blocks during casting.
However, automated block molding processes often cannot
provide blocks of varying size with a high level of detail
or ornamentation having the required structural integrity.
For example, wet concrete fill used in the manufacture of
blocks often transfers moisture to the stripper shoe during
- 2 -




20 609 3 4
the process of compaction. Once wet, the stripper shoe
becomes sticky due to the moisture present at its surface.
As a consequence, fill material may stick to the stripper
shoe.
The shoe may become fouled with mix, especially in
indented areas used to form ornamentation, design, or detail
on the blocks. In turn, various intended features of the
block may be malformed or completely omitted as indentations
or patterning on the stripper shoe are clogged or fouled with
concrete mix. Ultimately this results in block features
which are malformed and further eroded during curing and use.
This problem fails to lend itself to the efficient
manufacture of blocks having the required structural
integrity and the intended level of detail or ornamentation.
However, in overcoming the problem of stripper shoe
fouling, several requirements of automated manufacture must
be satisfied. The elements of the block molding machine must
withstand automated block molding processes which often
involve a high degree of vibration, dirt, and compression,
among other environmental stresses. Electrical elements are
often not capable of surviving over a long term period under
these conditions. Further, head assemblies must be
serviceable to provide for operator safety as well as easy
disassembly.
- 3 -



20 609 3 4
As a result, a need exists for a non-fouling stripper
shoe and stripper shoe/mold assembly allowing for the
formation of concrete masonry blocks of a high level of
detail which at the same time provides for easy
serviceability, operator safety, and longevity in an
environment of high manufacturing stress.
Summary of the Invention
In accordance with the invention there is provided a
heated stripper shoe comprising a stripper shoe plate, and
at least one removable heat element positioned within the
heat block.
In accordance with another aspect of the invention there
is provided a heated stripper shoe and mold assembly for the
manufacture of composite masonry blocks comprising a stripper
shoe plate, a heat block positioned on the heated stripper
shoe, a heat element inserted within the heat block, a heat
shroud positioned over the heat block, means for attaching
the heated stripper shoe to the block machine head, and a
mold.
In accordance with a further aspect of the invention
there is provided a method of using the shoe and mold
assembly disclosed herein.
I have found that by applying heat, through the stripper
shoe, to the concrete fill adjacent the desired feature or
the point of detail or ornamentation, the fill dries and
hardens quickly. The fill does not adhere to and foul the
- 4 -



20 609 3 4
stripper shoe lower surface. Heat transmitted from the heat
elements through the shoe contacts the fill during
compression and evaporates excess water from the surface of
the fill. Heat prevents moisture from forming on the lower
surface of the shoe and, in turn, dissipates any opportunity
for an adhesive effect between the shoe and each subsequent
batch of fill or mix.
The invention allows for molding blocks of all sizes,
having high levels of detail, without fouling the stripper
shoe or malforming the block or block feature. Through use
of the invention, blocks having features of minimal size can
be formed with high precision and structural integrity. nI
its preferred mode the invention incorporates a stripper shoe
which has a heat element, detachably mounted to the shoe
upper side, adjacent the indentation in the shoe lower side.
The design of the invention withstands environmental stresses
such as vibration, dirt, and compression and offers a system
which is easily disassembled for repair or modification
without risk to the operation.
Brief Description of the Drawings
FIGURE 1 is an exploded perspective view of the heated
stripper shoe/mold assembly in accordance with one embodiment
of the claimed invention.
FIGURE 2 comprises a perspective view of the heated
stripper shoe/mold assembly depicted in Figure 1.
FIGURE 3 is a top plan view of the heated stripper shoe
- 5 -




depicted in Figure 1. 2 0 6 4 9 3
FIGURE 4 depicts a partial cross-sectional view of the
heated stripper shoe shown in Figure 2.
FIGURE 5 is a top plan view of the mold depicted in
Figure 1.
FIGURE 6 is a perspective view of a concrete masonry
block made in accordance with the embodiment of the claimed
invention shown in Figure 1.
Detailed Description of the Preferred Embodiments
The invention comprises a heated stripper shoe, a heated
stripper shoe~mold assembly and a method of forming concrete
masonry blocks with the shoe and mold assembly.
THE STRIPPER SHOE~MOLD ASSEMBLY
Turning to the Figures wherein like parts are designated
with like numerals throughout the several views, Fig. 1 shows
a stripper shoe and.mold assembly 8. The stripper shoe and
mold assembly generally includes a stripper shoe plate 30,
having a lower side 33 and an upper side 35. The stripper
shoe plate 30 may have indentations to form block edges or
details such as those shown at 31 on the shoe lower side 33,
see also Fig. 2. Heat blocks 32 may be positioned on the
stripper shoe plate upper side 35. Heat elements 34 may be
positioned or inserted within the heat blocks 32.
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.. 2~ 609 3 4
Positioned over the heat blocks 32 on the upper surface
of the shoe plate is a heat shroud 40. The heat shroud 40
has a lower side 43 and an upper side 45. The heat shroud
lower side 43 has indentations 42 positioned to cover the
heat blocks 32 once the heat shroud 40 is positioned over
the upper surface 35 of the stripper shoe plate 30, (see also
Fig. 4).
Also shown in Fig. 1 is the standoff 50 which attaches
the stripper shoe assembly 8 to the block machine head (not
shown). The standoff 50 is capable of spacing the stripper
shoe plate 30 appropriately in the block machine and
insulating the head from the heat developed at the surface
of the stripper shoe plate 30.
The assembly also comprises a mold 20 having an interior
perimeter designed to complement the outer perimeter of the
stripper shoe plate 30. The mold generally has an open
center 25 bordered by the mold walls. In fact, the mold may
take any number of forms or embodiments such as those
depicted in U.S. Patent No. 5,062,610,
Positioned beneath the mold is a pallet 10 used to
contain the concrete fill in the mold and transport finished
blocks from the molding machine. The stripper shoe assembly
8 may be seen in Fig. 2 in its assembled form.
_ 7 _




2p sp9 3 4
The stripper shoe 30 serves as a substrate on which the
heat elements 34 and heat blocks 32 are contained. Further,
the stripper shoe plate 30 also functions to form the body
of the block as well as detail in the blocks through
indentations in the stripper shoe lower surface 33, see Fig.
4. In use, the stripper shoe 30 functions to compress fill
positioned in the mold and, once formed, push or strip the
block from the mold 20.
The stripper shoe plate 30 may take any number of designs
or forms including ornamentation or structural features
consistent with the block to be formed within the mold. Any
number of steel alloys may be used in fabrication of the
stripper shoe as long as these steel alloys have sufficient
resilience and hardness to resist abrasives often used in
concrete fill. Preferably, the stripper shoe 30 is made from
steel alloys which will resist continued compression and
maintain machine tolerances while also transmitting heat from
the heat elements through the plate 30 to the fill. In this
manner, the total thermal effect of the heat elements is
realized within the concrete mix.
Preferably, the stripper shoe plate 30 is made from a
carbonized steel which may further be heat treated after
forging. Preferred metals include steel alloys having a
Rockwell "C"-Scale rating from about 60-65 which provide
optimal wear resistance and the preferred rigidity.
Generally, metals also found useful include high grade carbon
_ g _




20 609 3 ~
steel of 41-40 AISI ( high nickel content, prehardened steel ) ,
carbon steel 40-50 (having added nickel) and the like. A
preferred material includes carbon steel having a structural
ASTM of A36. Preferred steels also include A513 or A500
tubing, ASTM 42-40 (prehardened on a Rockwell C Scale to 20
thousandths of an inch). The stripper shoe plate may be
formed and attached to the head assembly by any number of
processes known to those of skill in the art including the
nut, ( 36A-36D) , washer ( 57 ) , and bolt 56A-56D mechanism shown
in Fig. 1.
One preferred heated stripper shoe design which
complements a two block mold is shown in Fig. 1. Sides 37
and 39 of the stripper shoe have an indentation 31 on the
shoe lower side 33. A heat block 32 is positioned over both
indentations 31. The outer perimeter of the stripper shoe
30 may generally complement the interior outline of the mold
20. Heat blocks 32 are preferably positioned adjacent to
each indentation 31 on the shoe lower side 33 to facilitate
the formation of that point of detail created by the
indentation 31 in the stripper shoe 30. While generally
shown with one form of indentation 31, the stripper shoe
plate 30 may be capable of forming any number of designs
through indentations in the shoe plate lower surface 33
depending on the nature of the block to be formed.
The invention may also comprise one or more heat elements
34, Fig. 1. Generally, the heat element 34 functions to
_ g _




2o so9 3 ~
generate and transmit radiant energy to the upper surface 35
of the stripper shoe 30. The heat elements are preferably
positioned adjacent indentation 31 in the shoe plate lower
surface 33.
Generally, any number of heat elements 34 may be used in
accordance with the invention. However, preferred heat
elements have been found to be those which will withstand
the heavy vibration, dirt and dust common in this
environment. Preferred heat elements are those which are
easily introduced and removed from the system. This allows
for easy servicing of the stripper shoe assembly without
concerns for injury to the operator through thermal exposure
or complete disassembly of mold 20, stripper shoe 30, shroud
40, and standoff 50.
The heat element may comprise any number of electrical
resistance elements, which may be, for example, hard wired,
solid state, or semiconductor circuitry, among others. One
system found preferable, (Figs. 1 and 3), is a cylindrical
heat element 34 inserted into fastening means such as heat
block 32. This heat element 34 is easily introduced into
the heat block 32 and held in the heat block by any number
of means such as a screw, bolt, or bracket inserted through
opening 38.
- 10 -




20 609 3 4
In this embodiment of the invention, the heat element 34
may generally run the length of heat block 32 and is
positioned parallel to edges 37 and 39 of the stripper shoe
30, Fig. 3. The heat element is also positioned at the
stripper shoe upper surface 35 preferably adjacent the
indentations 31 formed in the sides 37 and 39 of the stripper.
shoe 30 at its lower surface 33. By this positioning, the
heat element 34 is able to apply heat to the stripper shoe
30 in the area where it is most needed, that is, where the
block detail (in this case, flange 62, see Fig. 6) is formed
in the concrete mix held by the mold. The heat element
34 may comprise any number of commercially available
elements. Generally, the power provided by the heat element
may range anywhere from 300 watts up to that required by the
given application. Preferably, the power requirements of the
heat element may range from about 400 watts to 1500 watts,
more preferably 450 watts to 750 watts, and most preferably
about 600 watts. Power may be provided to the heat elements
by any number of power sources including for example, 110
volt sources equipped with 20 to 25 amp circuit breakers
which allow the assembly to run off of normal residential
current. If available, the assembly may also run off of
power sources such as 3-phase, 220 volt sources equipped with
50 amp circuit breakers or other power sources known to those
of skill in the art. However, the otherwise low power
requirements of the assembly allow use in any environment
- 11 -




20 609 3 4
with minimal power supplies.
Elements found useful in the invention include cartridge
heaters, available from Vulcan Electric Company, through
distributor, such as Granger Industrial Co. of Minnesota.
These elements have,all been found to provide easy assembly
and disassembly in the stripper shoe of the invention as well
as good tolerance to vibration, dirt, dust, and other
stresses encountered in such an environment.
Generally, the heat elements may be activated by hard
wiring 70, Figs . 1 and 3, as well as any other variety of
electrical feeds known to those of skill in the art. If hard
wiring is used provision may be made to circulate this wiring
70 through the shroud 40 and standoff 50 by various openings
48 and 58, respectively. The heat element 34 may be
externally controlled through any number of digital or
analogue mechanisms, known to those of skill in the art
located at an external point on the block machine.
The invention may also comprise means of attaching the
heat element 34 to the stripper shoe 30 such as heat block
32, Fig. 1. In a preferred embodiment of the invention, the
heat block 32 also contains the heat generated by the heat
element 34 from the head assembly and directs that heat
energy towards the stripper shoe 30.
- 12 -




20 609 3 4
In accordance with these functions, the heat block 32
disclosed herein may take any number of shapes or forms and
comprise any number of different materials. Preferably, the
heat block 32 may be designed to provide a highly serviceable
releasable containment area for the heat element 34. The
heat block may be positioned on the upper surface 35 of the
stripper shoe 30 adjacent any corresponding area of detail
on the lower surface 33 of the stripper shoe 30.
In one embodiment of the invention, the heat block 32
preferably takes the shape of a three dimensional rectangle
having a square cross section, Figs. 1, 3 and 4. The heat
block 32 may be hollowed or bored out to allow insertion of
a heat element 34 into the block 32. The heat block 32 may
also have any number of holes or apertures useful in the
insertion of screws, bolts, or other means useful holding
the heat element 34,within the block 32.
Generally, the heat block 32 may be held on the stripper
shoe by any number of means including welding, bolting and
the like. As can be seen in Figure 4, the heat block 32 may
have any variety of cross sectional shapes including that of
a square or rectangle. Once the heat element 34 is placed
into the heat block 32, wiring may be played out from the
heat element and inserted through the heat shroud 40 and head
standoff 50 to the appropriate connection at the top of the
head.
- 13 -




20 609 3 4
The heat block 32 may comprise any number of materials
which allow for the releasable fixing of the block 32 and
heat element 34 to the shoe 30. Preferably, the heat block
32 has an open bottom which allows the element 34 to lie
flush and in contact with the stripper shoe upper surface
35. This configuration allows free transmission of heat to
the upper surface of the stripper shoe while precluding or
insulating the head structure from the heat generated by the
heat element 34.
Generally, the heat block may comprise any number of
metal alloys including A36 cold roller steel, hot rolled
carbon steel. The preferred metal has been found to be A36
cold rolled steel due to its low conduction of heat which
thereby further thermally insulates the shroud 40 and
standoff 50.
The stripper shoe may also comprise a heat shroud 40,
Fig. 1, which thermally shields or insulates the head
standoff 50 and molding machine. The heat shroud 40 also
functions to focus the heat generated by the heat elements
back onto the stripper shoe 30.
The heat shroud 40 may take any number of shapes of
varying size in accordance with the invention. The heat
shroud 40 should preferably contain the heat elements 34.
To this end, the heat shroud 40 preferably has a void 42
formed within its volume so that it may be placed over the
heat block 32 positioned on the upper surface 35 of the
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Zp gp9 3 4
stripper shoe 30. At the same time, the shroud 40 is
preferably positioned flush with the stripper shoe upper
surface 35.
Preferably, there is a space 41, Fig. 4, between the
upper surface of the heat block 32 and the opening or void
in the heat shroud 40. Air in this additional space 41 also
serves to insulate the standoff and mold machine from the
heat created by the heat element 34 contained within the
block 32.
Generally, the heat shroud 40 may comprise any metal
alloy insulative to heat or which is a poor conductor of
thermal energy. Metal alloys such as brass, copper, or
composites thereof are all useful in forming the heat shroud
40. Also useful are aluminum and its oxides and alloys.
Alloys and oxides of aluminum are preferred in the formation
of the heat shroud 40 due to the ready commercial
availability of these compounds. Aluminum alloys having an
ASTM rating of 6'061-T6 and 6063-T52 are generally preferred
over elemental aluminum.
The assembly may additionally comprise a head standoff
50, Fig. 1, to position, aid in compression, and attach the
head assembly to the block machine.
Generally, the head standoff 50 may comprise any number
of designs to assist and serve this purpose. The head
standoff may also be used to contain and store various wiring
or other elements of the stripper shoe assembly which are not
- 15 -




20 009 3 4
easily housed either on the stripper shoe 30, or the heat
shroud 40.
The head standoff 50 may comprise any number of metal
alloys which will withstand the environmental stresses of
block molded processes. Preferred metals include steel
alloys having a Rockwell "C"-Scale rating from about 60-65
which provide optimal wear resistance and the preferred
rigidity.
Generally, metals found useful in the manufacture of the
head standoff mold of the present invention include high
grade carbon steel of 41-40 AISI (high nickel content,
prehardened steel), carbon steel 40-50 (having added nickel)
and the like. A preferred material includes carbon steel
having a structural ASTM of A36. Generally, the head
standoff 50 may be made through any number of mechanisms
known to those of skill in the art.
Preferably, the standoff has an open design allowing for
quick dissipation of heat. One preferred form of the head
standoff 50 can be seen in Figs. 1 and 2. In this embodiment
the standoff has holes 58 for receipt of the studs 36A-36D
stemming from the stripper shoe plate 30. Opening 58 allows
for the further stringing of wiring 70 stemming from the heat
elements 34. The standoff 50 may be further attached to the
block machine through openings 55 in the top plate 54 of the
standoff 50.
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20 609 3 4
As can be seen in Figures 1, 2 and 5, the invention may
also comprise a mold 20. The mold generally functions to
facilitate the formation of the blocks. Accordingly, the
mold may comprise any material which will withstand the
pressure to be applied. to the block filled by the head.
Preferably, metal such as steel alloys having a Rockwell "C"-
Scale rating from about 60-65 which provide optimal wear
resistance and the preferred rigidity.
Generally, other metals found useful in the manufacture
of the mold of the present invention include high grade
carbon steel of 41-40 AISI (high nickel content, prehardened
steel), carbon steel 40-50 (having added nickel) and the
like. A preferred material includes carbon steel having a
structural ASTM of A36.
Mold 20 useful in the invention may take any number of
shapes depending on.the shape of the block to be formed and
be made by any number of means known to those of skill in
the art. Generally, the mold is produced by cutting the
steel stock, patterning the cut steel, providing an initial
weld to the pattern mold pieces and heat treating the mold.
Heat treating generally may take place at temperatures
ranging from about 1000°F to about 1400°F from 4 to 10 hours
depending on the ability of the steel to withstand processing
and not distort or warp. After heat treating, final welds
are then applied to the pieces of the mold.
- 17 -



20 609 3 4 ~'
Turning to the individual elements of the mold, the mold
walls generally function according to their form by
withstanding the pressure created by the press. Further,
the walls measure the height and the depth of resulting
blocks. The mold walls must be made of a thickness which
will accommodate the processing parameters of the block
formation given a specific mold composition. Preferably,
the mold walls range in thickness from about 3~8 inch to
about 1 inch, preferably from about 1~2 inch to about 3~4
inch.
In one preferred embodiment of the invention, Figs. 1,
2 and 5 the mold may be fitted to form two blocks comprising
four walls and an open central cavity 25, Fig. 5. The four
walls are generally a front wall 21, a back or rear wall 3,
and first and second opposing sidewalls, 22 and 24. Flanges
such as 26-29 Fig. 5, may be formed on the interior sides of
the mold walls to form ornamental features in the blocks or
assist in forming splitting points for blocks that are formed
in tandem or "siamese".
Block Molding
In operation, the assembly 8 is generally positioned in
the block molding machine atop of a removable or slidable
pallet 10, Figs. 1 and 2. The mold 20 is then loaded with
block mix or fill. As configured in Figures 2 and 5, the
mold 20 is set to form two blocks simultaneously in a
"siamese" pattern. Once formed and cured, these blocks may
- 18 -



20 809 3 4
be split along an edge created by flanges which may be
positioned on the interior of sidewalls 22 and 24 generally
along axis A'- A, Fig. 5. Prior to compression, the upper
surface of the mold is vibrated to settle the fill and
scraped or raked with the feed box drawer (not shown) to
remove any excess fill. The mold is then subjected to
compression directly by the stripper shoe 30 through head
assembly 8.
Upon compression, the stripper shoe 30 forces block fill
towards either end of the mold into the stripper shoe
indentation 31 to create a flange 62 in the formed block 60,
Fig. 6. This flange may range in size for example from about
3~8" to 2", preferably about 2~3" to 1-1~2", and most
preferably about 2~4" to 1-1~4".
In accordance with the invention, this indentation 31 is
heated by element 34 contained in the heat block 32 so that
flanges of minimal size and varying shape may be formed
without the build up of fill on the stripper shoe 30 at
indentation 31. By doing so, the assembly may be used in the
automatic manufacture of blocks by machine.
Blocks may be designed around any number of different
physical properties in accordance with ASTM Standards
depending upon the ultimate application for the block. For
example, the fill may comprise from 75 to 95~ aggregate being
sand and gravel in varying ratios depending upon the physical
characteristics which the finished block is intended to
- 19 -




20 609 3 4
exhibit. The fill generally also comprises some type of
cement at a concentration ranging from 4~ to 10~. Other
constituents may then be added to the fill at various trace
levels in order to provide blocks having the intended
physical characteristics.
Generally, once determined the fill constituents may be
mixed by combining the aggregate, the sand and rock in the
mixer followed by the cement. After one to two and one-half
minutes, any plasticizers that will be used are added. Water
is then introduced into the fill in pulses over a one to two
minute period. The concentration of water in the mix may be
monitored electrically by noting the electrical resistance
of the mix at various times during the process. While the
amount of water may vary from one fill formulation to another
fill formulation, it generally ranges from about 1~ to about
6~.
Once the mold has been filled, leveled by means such as
a feed box drawer, and agitated, a compression mechanism such
as a head carrying the inventive assembly converges on the
exposed surface of the fill. The stripper shoe assembly 30
acts to compress the fill within the mold for a period of
time sufficient to form a solid contiguous product.
Generally, the compression time may be anywhere from 0.5 to
4 seconds and more preferably about 1.5 to 2 seconds. The
compression pressure applied to the head ranges from about
1000 to about 8000 psi and preferably is about 4000 psi.
- 20 -




2o so9 3 ~
Once the compression period is over, the stripper shoe
30 in combination with the underlying pallet l0 acts to strip
the blocks 60 from the mold 20. At this point in time the
blocks are formed. Any block machine known to those of skill
in the art may be used in accordance with the invention. One
machine which has been found useful in the formation of blocks
is a Besser V-3/12 block machine.
Generally, during or prior to compression the mold may
be vibrated. The fill is transported from the mixer to a hopper
which then fills the mold 20. The mold is then agitated for
up to 2 to 3 seconds, the time necessary to ensure the fill has
uniformly spread throughout the mold. The blocks are then
formed by compressive action by the compressive action of the
head. Additionally, this vibrating may occur in concert with
the compressive action of the head onto the fill in the mold.
At this time, the mold will be vibrated for the time in which
the head is compressed onto the fill.
Once the blocks are formed, they may be cured through
any means known to those with skill in the art. Curing
2G mechanisms such as simple air curing, autoclaving, steam curing
or mist curing, are all useful methods of curing the block of
the present invention. Air curing simply entails placing the
blocks in an environment where they will be cured by open air
over time. Autoclaving entails placing the blocks in a
pressurized chamber at an elevated temperature
- 21 -



20 fi09 3 4
for a certain period of time. The pressure in the chamber
is then increased by creating a steady mist in the chamber.
After curing is complete, the pressure is released from the
chamber which in turns draws the moisture from the blocks.
Another means for curing blocks is by steam. The chamber
temperature is slowly increased over two to three hours and
then stabilized during the fourth hour. The steam is
gradually shut down and the blocks are held at the eventual
temperature, generally around 120 - 200°F for two to three
hours. The heat is then turned off and the blocks are
allowed to cool. In all instances, the blocks are generally
allowed to sit for 12 to 24 hours before being stacked or
stored. Critical to curing operations is a slow increase in
temperature. If the temperature is increased too quickly,
the blocks may "case-harden". Case hardening occurs when the
outer shell of the block hardens and cures while the inner
region of the block remains uncured and moist. While any of
these curing mechanisms will work, the preferred mechanism
is autoclaving.
Once cured the blocks may be split if they have been cast
"siamese" or in pairs. Splitting means which may be used in
the invention include manual chisel and hammer as well as
machines known to those with skill in the art. Splitting
economizes the production of blocks of the present invention
by allowing the casting of more than one block at any given
- 22 -




2o so9 3 4
time.
In one preferred embodiment of the invention, a block 60
such as that shown in Fig. 6 is cast in pairs, joined at
surface 64. The block is formed top side 68 down with flange
62 directed upwards and positioned at either end of the mold
20 at sides 21 and 23, see Fig. 5. When cast in pairs, the
blocks 60 may be cast to have indentations or groove created
by flanges 26-29 on their side surfaces between the two
blocks. Flanges may also be positioned on the interior of
the mold side walls to provide a natural weak point or fault
which facilitates the splitting action when positioned along
axis A'-A. The blocks may be split in a manner which
provides a front surface 64 which is smooth or coarse, single
faceted or multifaceted, as well as planar or curved.
Preferably, splitting will be completed by an automatic
hydraulic splitter. When split, the blocks may be cubed and
stored.
The above discussion, examples and embodiments illustrate
our current understanding of the invention. However, since
many variations of the invention can be made without
departing from the spirit and scope of the invention, the
invention resides wholly in the claims hereafter appended.
- 23 -

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date 1999-12-28
(22) Filed 1992-02-10
(41) Open to Public Inspection 1993-08-11
Examination Requested 1995-08-22
(45) Issued 1999-12-28
Deemed Expired 2006-02-10

Abandonment History

Abandonment Date Reason Reinstatement Date
1998-03-23 R30(2) - Failure to Respond 1999-02-19

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $0.00 1992-02-10
Registration of a document - section 124 $0.00 1993-04-23
Maintenance Fee - Application - New Act 2 1994-02-10 $100.00 1994-01-26
Maintenance Fee - Application - New Act 3 1995-02-10 $100.00 1995-01-18
Maintenance Fee - Application - New Act 4 1996-02-12 $100.00 1996-02-07
Maintenance Fee - Application - New Act 5 1997-02-10 $150.00 1997-02-10
Maintenance Fee - Application - New Act 6 1998-02-10 $150.00 1998-02-09
Maintenance Fee - Application - New Act 7 1999-02-10 $150.00 1999-02-08
Reinstatement - failure to respond to examiners report $200.00 1999-02-19
Final Fee $300.00 1999-09-23
Maintenance Fee - Patent - New Act 8 2000-02-10 $150.00 1999-12-30
Maintenance Fee - Patent - New Act 9 2001-02-12 $150.00 2001-01-18
Maintenance Fee - Patent - New Act 10 2002-02-11 $200.00 2002-01-07
Maintenance Fee - Patent - New Act 11 2003-02-10 $200.00 2003-01-06
Maintenance Fee - Patent - New Act 12 2004-02-10 $200.00 2003-12-16
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
BLOCK SYSTEMS INC.
Past Owners on Record
WOOLFORD, MICHAEL E.
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Cover Page 1999-12-14 1 38
Cover Page 1994-02-19 1 35
Abstract 1994-02-19 1 41
Claims 1994-02-19 5 222
Drawings 1994-02-19 3 163
Abstract 1999-04-14 1 20
Description 1999-04-14 22 812
Claims 1999-04-14 7 271
Description 1994-02-19 22 1,097
Representative Drawing 1998-09-01 1 23
Representative Drawing 1999-12-14 1 16
Correspondence 1999-09-23 1 30
Office Letter 1992-09-16 1 55
PCT Correspondence 1992-10-28 1 19
Office Letter 1995-09-07 1 26
Office Letter 1992-02-10 1 24
Prosecution Correspondence 1995-08-22 1 32
Prosecution Correspondence 1999-02-19 3 79
Examiner Requisition 1997-09-23 2 38
Prosecution Correspondence 1996-03-21 2 38
Prosecution Correspondence 1995-10-03 1 29
Prosecution Correspondence 1995-05-09 1 31
Fees 1997-02-10 1 34
Fees 1996-02-07 1 31
Fees 1995-01-18 1 37
Fees 1995-01-26 1 29