Note: Descriptions are shown in the official language in which they were submitted.
WO 9S/32083 2 1 6 7 3 0 ~ PCT/US95/06166
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METHOD OF MANUFACTURING A BLOCK
BACKGROUND OF THE rNVENTION
1. Field of the Invention
The present invention is directed to the field of l~n~1sc~ping and
blocks used to construct a decorative and functional border, curb or edge,
and a method of m~mlf~cturing the blocks. The present invention may be
readily r~llor~ d onto existing common edging materials or installed
10 without use of such edging m~tçri~l~ The present invention also may be
used as an edge restraint for use with paving stones or bricks or to provide
decorative accent lines of contrasting color and texture in paver brick or
stone in~t~ tions.
2. Description of the Prior Art
Numerous methods and materials exist for the construction of
borders, curbs or edging for landscaping or site improvement work. Such
borders, edges or curbs serve several func*ons. First, they are decorative,
and provide an orderly transi*on from a garden area to a lawn, or from a
lawn to a sidewalk, etc. Second, they serve to separate different areas with
20 di~lelll forms of plant life or other landscaping element~, thereby reducing
m~inten~nce requirements such as removing weeds, or l-;.. ;l~g back plant
life that would otherwise spread. Third, they can ease the process of lawn
mowing by elimin~*ng the need to hand trim the border areas of the lawn
after mowing the main areas with a mechanical lawn mower.
One method for the construc*on of edging~ for use around gardens
or to divide sec*ons of a garden involves the use of lengths of flexible
metal or plas*c edging m~tçri~l~ that are anchored by ~igging a trench,
placing the edging m~teri~l anchoring the edging m~t~ri~l by driving spikes
WO 9S132083 PCTIUS95/06166
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216730~ -
through it into the ground, and then filling the trench with dirt. Such
methods are common and relatively inexpensive, but have several
disadvantages. First, such materials do not have a natural, yet orderly
appearance that is aesthetically pleasing in a landscaping application,
5 having inste~d a man-made appea~ ce. Second, such materials are not
easily fixed in straight lines or measured curves due to their flexible nature.
Third, such materials are susceptible to damage during lawn mowing, and
do not provide a "mowing strip" which would allow the wheels of a lawn
mower to follow the contour of the edging and lessen the need for hand
10 L~ along the borders of the lawn. Four~, such edgin~ are
susceptible to heaving from frost action in climates where the ground
freezes.
Another method of providing an edging is the use of numerous
natural stones or man-made bricks or blocks. Such stones or bricks are
15 installed by rli~ing a shallow trench and placing the stones or bricks more
or less continuously along the length of the trench. Such m~tçri~l~ may also
simply be placed on top of the ground without ~liggin~ a trench. Natural
stone has long been used for this application, but lacks the advantages of
the present invention for several reasons. First, natural stone is typically of
20 irregular shapes and requires labor intensive fitting of the natural stones
along the border or edging or costly cutting of the pieces to fit. This
irre~ rity also makes natural stone difficult to accommodate lawn
mowing, and precludes the placement of a mowing strip. Bricks or
rectangular blocks may also be used for lawn edging using a similar
25 in~t~ *on techniques. Rect~n~ r blocks do not lend themselves to the
construction of curvilinear e-lgingc, which are found in most l~n(lsc~ping
2167~05
WO 95/32083 PCT/US95/06166
applications, because they must be cut to avoid gaps that may allow
penetration of grass roots or other plant life and to provide an orderly
appearance.
Another method for forming an edging or border has been to pour a
5 concrete edging in place. The disadvantages of this method are the expense
and effort involved. To install such an e~lging an adequate trench must be
dug, then forms must be constructed laying out the line of the edging, then
the concrete must be mixed, poured, and allowed to cure. Such edgings
may also require the placement of exp~n.cion material filled joints, and are
10 susceptible to cracking. Electrical wiling, as for outdoor lightin~ cannot bereadily installed in such structures, and if installed, cannot be m~intained
and inspected without destruction of the edging In addition, such edgings
are not readily removed in the event a change in the contour of the lawn or
garden border is desired. Finally, such edgings do not provide a desirable
15 natural appearance.
There have also been efforts to address some of these deficiencies in
the prior art through masonry block design~ and wet cast concrete designs
that are meant specifically for use as an edgin~. These designs either are
composed of single units that are capable of being laid in straight or curved
20 lines, or multiple unit systems with curved and straight pieces. These
products are produced on concrete masonry block or paving m~c.hines7 or
through pre-casting with numerous concrete forms, and are designed to
allow the construction of curved edgings. These products, while an
improvement over using a simple rectan~-lar brick, do not provide a natural
25 appearance due to their molded appearance from the m~mlfacturing
process. None of these edges have a mowing strip incorporated as part of
WO 9S/32083 ! ~ PCr/US95/06 166
216730'J
*s process design. Moreover, these ~eei~e cannot be lel orllled over an
existing plastic or metal e~lging, and cannot accommodate elect~ical wires
for inet~ tion of low voltage elect~ical lan-lsc~ping lights.
Another field in which the present invention may be used is the field
5 of curbs or edge r~sllai~ for surfaces that are paved with concrete or brick
pavers or paving stones, or asphalt or concrete or other paving materials.
An example of curbing is disclosed in U.S. Pat. No. 4,971,475. Such
curbing suffers from many of the limitAtions discussed above regarding
e~lgin~ e.g., lack of curvilinear construction without time-consuming and
10 costly on-site cutting, susceptibility to heaving from freeze/thaw cycles, and
inability for receiving electrical or other conduits.
Examples of paver stones are disclosed in U.S. Pat. Nos. 4,711,599
and 4,834,575. Typical paver edging lesl~ are plastic or metal strips
fixed in a manner similar to the flexible edging materials discussed above.
15 For similar reasons, the paver edge l~ mls are also difficult to fix in
straight mç~ellred curves, and are susceptible to heave from freeze/thaw
cycles. Additionally, such les~ do not provide a conduit for drainage
or elect~ical lines.
Another aspect of the present invention is a method of m~mlf~cturing
20 landscaping blocks having a groove and/or an angled end. Examples of
masonry block molding are disclosed in U.S. Patent Nos. 5,062,610 and
4,335,549. However, these patents do not disclose how to mold blocks
having an angled end and a split top surface.
Accordingly, it is an object of the present invention to provide a
25 landscaping block that is constructed with a groove or channel designed
into the bottom surface of each landscaping block so that each block may be
2167~5
WO 9S/32083 rCI/US95/06166
._
installed over prevalent exi~ting e~lgin~ or installed with or without
inexpensive cormectors of a design disclosed herein.
Another object of the present invention is to provide a l~n~c~ping
block that has a mowing or paver support edge on one or both sides of the
5 unit to ease lawn mowing or to provide an interlock ledge for the placement
of pavers and surface to secure with a spike. This ledge or lip allows
efficient lawn mowing in the vicinity of the e~lging This lip also serves as
a base line for the screening off of the base material required for the
installation of a layer of paving stones or bricks and provides an edge
10 structure that assures the integrity of the base layer of sand commonly used
n(lçrnç~th the paving stones.
Another object of the present invention is to provide a landscaping
block such that the uppermost surface of each unit has a natural stone
appearance.
Another object of the invention is to provide a l~n~l~c~ring block
with sides that taper from the lip to the bottom along the block's length to
better resist the effects of frost heave, and to ease inct~ tion.
Another object of the invention is to provide a l~n~lsc~ping block
with means to accommodate the passage of electrical wiring for outdoor
20 lighting
A still further object of the invention is to provide a l~n~lsc~ping
block that combines some or all of the elements of each of the various
objects disclosed above.
Another object of the present invention is to provide a l~n~lsc~ping
25 block system that is constructed of blocks that are capable of forming either
WO 95/32083 PCr/US95/06166
216730~
straight or curved edges, curbs or borders and incorporate some or all of the
elements of each of the objects disclosed above.
Another object of the invention is a method of m~nllf~cturing
l~n~l~c~ping blocks vertically in a mold and in pairs, where the top of each
5 block has a split surface.
These and other objects of the present invention will become
app~ent with reference to the drawings, the description of the ple~lled
embodiment and the appended claims.
SUMMARY OF THE INVENTION
In contrast to the prior art, the present invention provides for an
improved landscaping block or edgin~ More particularly, the present
invention relates to a landscaping block having a top and a generally
opposed bottom, and first and second generally opposed sides, where each
side extçntlc from the top to the bottom. The block further includes first
15 and second generally opposed ends, each end extending from the top to the
bottom and from the first side to the second side. The first side includes a
first upper face çxtenrling from the top downward to an inner edge of a first
lip, and the first lip çxten~ outward from the first upper face to an outer
edge of the first lip for alignment of the outer edge of the first lip with an
20 upper surface of a substrate when the block is inserted in the substrate.
Further, the block has a first lower face çxtenllin.~ from the outer edge of
the first lip to the bottom. In accordance with a further aspect of the
invention, the second side comprises a second upper face exten~ling from
the top downward to an inner edge of the second lip. The second lip
25 extends outward from the second upper face to an outer edge of the second
lip for alignment of the outer edge of the second lip with an upper surface
WO9S/32083 2167~n~5 PCT/US9S/06166
of a substrate when the block is inserted into the substrate. Additionally,
the second lower face extçn~ from the outer edge of the second lip to the
bottom.
In accordance with a further aspect of the invention, the first lower
face is tapered inward from the outer edge of the first lip to a first bottom
edge of the first lower face, and the second lower face is tapered inward
from the outer edge of the second lip to a second bottom edge of the second
lower face.
In accordance with a further aspect of the invention, the block
further comprises first and second generally opposed interior walls
extçn~ing from the bottom toward the top, defining a groove opening into
the bottom and sxtçn(ling from the first end to the second end. The groove
may have different cross-sectional shapes as viewed from one of the ends.
In accordance with one embodiment of the invention, the groove has a
generally rect~n~ r cross-sectional shape. In another aspect of the
invention, the groove has a generally key-hole cross-sectional shape. In
another aspect of the invention, the groove has a curved cross-sectional
shape towards the top and a generally rect~n~ r cross-sectional shape
adjacent the bottom.
In accordance with another aspect of the invention, the groove is
tapered from the first end to the second end. In accordance with another
aspect of the invention, the first end defines an acute angle ~om the first
side to the second side and the second end is generally perpendicular to the
first and second sides. Preferably, the acute angle is in the range from ten
to ei~hteen degrees. Additionally, the first and second lips extend at least
one-fourth inch from the inner edge.
WO 95132083 . ~ PCI/US95/06166
216730~
In accordance with another aspect of the invention, a l~nrlec.~ping
system is provided. More par~icularly, the system relates to means for
anchoring landscaping blocks in a fixed position relative to a substrate
having an upper surface, the anchoring means being partially embedded in
5 the substrate. The system further includes one or more l~n~lsc~ping blocks,
each of the blocks cnmpri.cing a top and a generally opposed bottom, first
and generally opposed sides, each side extçn-ling from the top to the
bottom, first and second generally opposed ends, each end extçn~ling from
the top to the bottom and from the first side to the second side, and the
10 bottom comprising means for coupling the blocks with the anchoring means
by receiving the ançhoring
In accordance with another aspect of the invention, a plurality of
landscaping blocks are provided, where each of the blocks comprised as a
top and generally opposed bottom, first and second generally opposed sides,
15 each side çxtçntling from the top to the bottom, first and generally opposed
ends, each end çxt~n-ling from the top to the bottom and from the first side
to the second side, the bottom compri.~ing first and second generally
opposed interior walls ext~n-ling from the bottom toward the top, ~lefining
groove opening into the bottom and çxten-ling from the first to the second
20 end. Further, the blocks are placed end to end, the bottom of each block
embedded in the substrate having an upper surface, the top of each block
above the substrate upper surface, and the blocks defining an edging and the
block grooves ~l~fining a con*nllous conduit.
In accordance with another aspect of the invention, a l~n~1ec~ping
25 system is provided having means for coupling landscaping blocks in an end
to end relations_ip with a plurality of blocks, each of the blocks compri~in~;
WO 9S/32083 2 1 6 7 3 0 ~ PCT/US95tO6166
_ 9 _
a top and a generally opposed bottom, first and second generally opposed
sides, each side exten-ling from the top to the bottom, first and second
generally opposed ends, each end extçn-1ing from the top to the bottom and
from the first side to the second side, the bottom comprising first and
5 second generally opposed interior walls exten~ling from the bottom toward
the top ~lçfining a groove opening into the bottom and extçntling from the
first side to the second side. The blocks are positioned end to end and
embedded in a substrate, and adjacent ends of adjacent blocks are
connected by coupling means ext~ntling into the grooves of the adjacent
10 blocks.
In accordance with another aspect of the invention, there is a method
of molding a block comprising a top and a generally opposed bottom, first
and second generally opposed sides, each side extending from the top to the
bottom, first and second generally opposed ends, each end ext~on~ing from
15 the top to the bottom and from the first to the second side, wherein the first
end defines an acute angle from the first side to the second side and the
second end is generally perpendicular to the first and second sides. The
method comprises the steps of positioning a platform in a mating position
under a mold. The mold cnmpri~es a top, a bottom, and a continuous
20 vertical wall ext~nl1ing from the mold top to the mold bottom ~çfining a
volume open at the top of the mold and further ~efining the cross-sectional
shape of the block. The inner wall comprises a first pair of opposed side
- walls defining the top and bottom of the block, and a second pair of
opposed side walls ~lefining the first and second sides of the block. The
25 second pair of opposed side walls are angled at the top of the mold to
define the first angled end of the block and the platform, positioned at the
WO 9S/32083 ! PCT/US95/06166
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216730~
bottom of the mold, defines the second end of the block. Additionally, the
method includes introducing a block forming substance into the volume and
colllp,~ssing the block forming substance in the volume from the top of the
mold with a shoe having an angle that is complementary to the angled top
5 end of the second pair of opposed side walls of the mold. Additionally, the
method includes the steps of moving the platform into a de-molding
position away from the mold and removing the shoe to leave the molded
block. The method may further include vibrating the mold and platform
after introducing a block-forming substance into the volume. Further, the
10 mold may comprise a plurality of volumes.
In accordance with another aspect of the invention, there is a method
of m~kin~ a first and second block, each block comprising a top and a
generally opposed bottom, first and second generally opposed sides, each
side extending from the top to the bottom, first and second generally
15 opposed ends, each end extending from the top to the bottom and from the
first to the second side, wherein the first end defines an acute angle from
the first side to the second side and the second end is generally
perpendicular to the first and second sides. The method comprises the steps
of positioning a platform in a mating position under a mold. The mold
20 comprises a top, a bottom, and a continuous vertical wall extending from
the mold top to the mold bottom defining a volume open at the top of the
mold and further defining a composite block having the cross-sectional
shape of the first and second block position so that the top of the first block
is parallel and connected to the top of the second block and the angled first
25 ends of the first and second blocks are at the top of the mold, wherein the
inner wall comprises a first pair of opposed sidewalls ~lefining the bottom
wo ss/32os3 - 11 2 1 6 7 3 0 ~ PCT/US95/06166
of the first block and bottom of the second block, and a second pair of
opposed sidewalls defining the first and second sides of the f~rst and second
blocks, the second pair of opposed sidewalls angled at the top of the mold
to define the first angled end of the first and second blocks, and the
platform at the bottom of the volume defining the second end of the first
and second blocks. Additionally, the method includes introducing a block
forming substance into the volume and co~llp~cssing the block-forming
substance in the volume from the top of the mold with a shoe angled
compl~ment~ly to the angled top end of the second pair of opposed
sidewalls of the mold. Additionally, the method includes moving the
platform into a de-molding position away from the mold and removing the
shoe to leave the composite block. Additionally, the method may further
inchlde splitting the composite block along the plane of the cormected tops
of the first and second blocks forming the separate, disconnected first and
second blocks. The method may further include vibrating the mold and
platform. Further, the mold may comprise a plurality of volumes. Further,
the block may be split by a splitting m~chine comprising a top splitting
blade having a serrated lower edge. Further, the ~dj~cent blocks remain
adjacent as a result of splitting the composite block.
DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of a landscaping block in accordance
with the invention.
Figure 2a is an end view of a l~nd~c~ping block in accordance with
the invention.
Figures 2b-2f are partial end views of ~lt~rn~te embotlimentc of a
landscaping block in accordance with the invention.
WO9S/32083 ~ - 12 - PCT/US95106166
216730~
Figure 2g is an end view of a l~n-lsc~ring block inserted into a
substrate in accordance with the invention.
Figures 3a-3c are end views of ~lt~ te embo~imçnt~ of a
landscaping block showing the groove in accordance with the invention.
5Figure 3d is an end view of a l~n~lsc~ping block positioned over a
pipe in accordance with the invention.
Figure 3e is an end view of a landscaping block positioned over
electrical wiring in accordance with the invention.
Figure 4a is a perspective view of anchoring means in accordance
10withtheinvention.
Figure 4b is a perspective view of an alternate embodiment of
anchoring means in accordance with the invention.
Figure 5a is a top view of a landscaping block in accordance with the
invention.
lSFigure Sb is a top view of an alternate embodiment of a lan~cc~ring
block in accordance with the invention.
Figure 5c is a top view of landscaping blocks aligned end to end to
form a straight border in accordance with the invention.
Figure 5d is a top view of l~n(15c~ping blocks aligned end to end to
20form a curved border in accordance with the invention.
Figure 5e is a top view of landscaping blocks aligned end to end to
form a curvilinear border in accordance with the invention.
Figure 6a is a perspective view of a l~ndsc~I)ing block system in
accordance with the invention.
25Figure 6b is a perspective view of an ~ltern~te embodiment of a
landscaping block system in accordance with the invention.
woss/320s3 2 1 6 73 0 5 PCT/US95/06166
Figure 6c is a perspective view of an ~ltçrn~*ve embodiment of a
landscaping block system in accordance with the inven*on.
Figure 7 generally shows the steps of ...~ r~cturing the l~n~lsc~ping
blocks of the present inven*on.
Figure 8 is a front view of a block molding m~chine.
Figure 9 is a perspec*ve view of an embodiment of the mold and
platform of the present inven*on.
Figure lOa is a top view of an embodiment of the mold of the present
invention.
Figure lOb is a top view of an ~ltçrn~te embodiment of the mold of
the present inven*on.
Figure 11 is a sectional view of an embodiment of the mold along
line x-x of the present inven*on.
Figure 12 is a perspective view of the compression head and shoe
~csembly of the present invention.
Figure 13 is a side view of the shoes of the present invention.
Figure 14 is a partial front view of the cut-offbar of the present
invention.
Figure 15 is a front view of a splitter of the present invention.
Figure 16 is a top view of an alternate embodiment of the mold of
the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to Figures 1 - 6c there is shown a landscaping block 1 of
the present invention. Block 1 is made of a rugged, weather-resist~nt
m~teri~ crelably pre-cast concrete. Other suitable materials are plastic,
reinforced fibers, wood, metal, and stone. As shown in Figure 1, block 1
WO 9S/32083 ~ - PCT/US95/06166
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216730~
includes a top 2, a generally opposed bottom 3, and first and second
generally opposed sides 4, 5, each side exten~ing from top 2 to bottom 3.
First and second generally opposed ends 6, 7 extend from top 2 to bottom 3
and from first side 6 to second side 7. Groove or channel 8 extends f-rom
5 bottom 3 into block 1 toward top 2, thereby having an opening at bottom 3,
and ext~n(l~ from first end 6 to second end 7.
In a plcrellcd embodiment of the invention, block 1 extends
a~pro,~;.,.~tely six inches from first end 6 to second end 7, four inches from
top 2 to bottom 3, and four inches from first side 4 to second side 5 at lip
10 12. With these rlimen~ions, block 1 is light enough for relatively easy
transport and placement, provides adequate separation height and width for
edging, as well as providing a deep enough mower strip to reduce hand-
l. ;.. ;-.g and allows for easy const~uction of a variety of straight and
curved edging p~tt~rn.~. However, in order to meet the requirements of
15 dirre~cnl applicahons, block 1 may have larger or smaller limçn~ions and
varymg proportlons.
As shown in Figure 2a, sides 4,5 each have an upper face 9 and a
lower face 10. Upper face 9 is generally above-ground when the block is in
use, providing the visual edging or separation. Lower face 10 is at and
20 below ground level and, in conjunction with groove 8, fixes block 1 in
place in a substrate, typically dirt, sand, or other natural material.
Upper face 9 ext~n-ls from top 2 dowl,wald to inner edge 11 of lip
12. Face 9 may be planar and, in a prcfcllcd embo-lim~nt includes beveled
edge 13 adjacent top 2. As shown in Figures 2b-2d, top 2 and face 9 may
25 have a variety of curved and/or textured shapes to meet the specific needs
W O 95t32083 2 1 6 7 3 0 S P~rtUS95/06166
- 15 -
of any given application. Also, Figures 2e and 2f disclose alternate
- embo-limçnt~ of block 1 with one or no lip 12.
Lip 12 defines a transition from upper face 9 to lower face 10.
Ledge 12 ext~ntls oulw~dly from upper face 9 to outer edge 14, at least
5 about one-fourth inch and ~efer~bly about five-eighths inch. As shown in
Figure 2g, ledge 12 provides a mowing edge or strip that allows the wheels
of a lawn mower to follow the conlou,~ of the block and allows the lawn
mower to cut the grass adjacent the mowing strip, lessening the need for
hand-l~ ng along the borders of a lawn.
In other applications of block 1, ledge 12: (1) provides an anchoring
surface for placçrnent of l~n(lsc~pe rock, etc; (2) serves as a screed board
leveling surface for paver in~t~ tions and provides interlock to prevent
deterioration or loss of sub-base m~t~ri~ls when used as a paver curb or
e~gin~ and (3) locks block 1 in place when used as an accent or
passageway for conduit through a paved surface.
Fxt~n-ling dowllw~ud from outer edge 14 of ledge 12, lower face 10
has alignment strip 15 for easier placement of block 1 in the substrate and
tapered portion 16 çxtentls to bottom edge 17. The adv~nt~ges of tapered
portion 16 are discussed below.
As shown in Figure 1, groove or channel 8 extends into block 1 from
bottom 3 toward top 2. In an embodiment shown in Figure 3a, groove 8 is
defined by generally opposed interior walls 18a, 18b. The width of slot 8,
- identifled by arrow D, is the distance between the opposed interior walls
18a, 18b and is wide enough to receive commonly available black plastic
edging 19. As shown in Figures 4a and 4b, edging 19 may have various
configurations. Typically, edging 19 have a lower bead or protrusion to
WO 9S132083 - ~CI/US95/06166
216730J
allowing nailing or spiking in place. Figure 4a shows commonly available
flexible black PVC edging or strip 20 having opposed vertical walls 21a,
21b, and a top 22 and a bottom 23 edge. As shown in Figure 4a, top edge
22 may include an elongated bead 24. As shown in Figure 4b, edging 19
5 may be a planar strip made of al----,;----"~ or other suitable material. F-l~ing
19 should be flexible to create the desired border shape and made of a
suitable material for use in the desired substrate. Typically, edging 19 is
partially embedded in a substrate by ~liggin~ a small trench, and also may
be fixed in place by stakes.
Cavity 8 allows block 1 to fit over the top of and receive edging 19
or, as shown in Figure 3b, block 1 can be locked onto edging 20 by the key-
hole cross-sectional configuration of slot 8. In the locking embodiment of
Figure 3b, opposed interior walls 18a, 18b define an upper ~nn~ r
receiving portion 25 for receiving the bead 24 of edging 20. Receiving
15 portion 25 has a lower opening that forms neck 26 which prevents bead 24
from moving downward out of upper receiving portion 25 without
substantial force excee-ling the normal forces of the ~ulloullding substrate
during freeze/thaw cycles. The lower portions of walls 18a, 18b preferably
taper oulw~d or diverge towards sides 4, 5. Also, groove 8 can be tapered
20 from one end 6 to the other end 7, i.e., the slot width increases from one
end 6 to the other end 7, for easier ~tt~çhment and det~.hment of block 1 to
strip 20.
In the embodiment shown in Figure 3a, interior walls 18a, 18b are
al)plo~ullately parallel, ~çfining a rect~n~ r region for receiving a planar
25 e~lging. In another embodiment shown in Figure 3c, interior walls define an
WO 9Sr32083 2 1 6 7 ~ 0 5 PCT/US95/06166
- 17-
upper curved shape at the top of groove 8 and a generally rect~n~ r cross-
sectional shape ~ cent the bottom, accommodating a variety of edging~.
Groove or çh~nnel 8 accomplishes several goals. First, blocks 1 can
be locked into place over exi~ting edging, which serves as an ~li nm~nt
5 guide, conce~ling the plastic or metal edging and providing an attractive,
natural-looking edging Second, slot 8 provides connection, coupling,
~ligning, and anchoring means, ~ci~ting in the inst~ tion of the edging.
Finally, groove 8 allows for passage of pipe or other conduit for irrigation
as shown in Figure 3d or electrical wiring as shown in Figure 3e along the
edging
In the embodiment of the invention shown in Figure 3b, tapered
portion 15 of lower face 10 on sides 4, 5 and diverging interior walls 18a,
18b provide several advantages. First, this embodiment is more easily
installed by allowing block 1 to be more easily inserted into the substrate or
15 soil than a flat bottomed surface. Second, this embodiment is more easily
inserted over edging 19 and locked into place. Third, this embodiment is
more resi~t~nt to frost heave than a flat bottomed surface, thereby ret~ ;..g
its position in the substrate over a period of years. Finally, this embodiment
allows block 1 to fit over pipes or conduits that would otherwise be too
20 wide.
The ends 6, 7 of block 1 provide another important aspect of the
invention. In an embodiment of the invention shown in Figure 5a, end 6 is
- angled a~l,roxi.. ~tçly 12 degrees from side 4 to side 5, while end 7 is
ap~rox;.n~tely perpendicular to sides 4, 5. Figure 5b shows another
25 embodiment of block 1 having an angled end 6, but without lip 12. A
ple~,led range of angles is 10-18 degrees. As shown in Figures 5c - 5e,
WO 95t32083 , `. ` PCT/US95/06166
216730~ 18-
straight-end/angled-end block configurations allow for various straight
(Figure 5c), curved (Figure 5d), curvilinear (Figure 5e) borders without
having to cut the blocks at the installation site. At least nine diLrelenl
shapes can be achieved using two blocks. In other embodiments, the blocks
5 may have both ends perpendicular to the sides, both ends angled from one
side to the other, or ends with di~.~l-l angles. Plefelled angles are those
divisible into 360 degrees (i.e. 9, 12, 15, 18 and 24 degrees) so that the
blocks can make a circle to be used around a tree, for example.
There are numerous options for the appearance of top 2 and upper
10 face 9 of sides 4, 5. Any of these surfaces can have a natural or "split"
surface, smooth s~ ce, COldul-)y or other striated surface.
When block 1 is installed as shown in Figure 2e, block 1 is inserted
into a substrate 40, which may be earth or other material. Lip 12,
pler~lably planar, and iqlignment strip 15 assist in placing block 1 in a
15 ~le~llcd position wherein lip 12 is coplanar with the ~ulluu-lding substrate.Lip 12 provides a mowing or spacer strip that sep~les top 2 and sides 4, 5
from the substrate by the length of lip 12. Lip 12 may be on one or both
sides of block 1 depending on the application.
A combination of blocks 1 can be used to create several l~n~l~c~ping
20 block systems. The first system is discussed above and shown
schematically in Figure 6a. A new or existing edging 19 provides means
for anchoring landscaping blocks 1 in a fixed position relative to the
substrate 40. Anchoring means 19 is partially embedded in the substrate.
Using edging strip 20 disclosed in Figure 4a, bottom edge 23 is embedded
25 in the substrate and bead 24 is above the upper surface of the substrate.
The bottom groove or coupling means 8 at the bottom 3 of each block 1 is
2 1 6 7 3 0 r3
WO 9S/32083 PCT/US95/06166
- 19-
placed over and receives anchoring means 19 and the lower face 10 of each
block 1 is also embedded in the substrate. The blocks 1 are aligned end to
end along strip 19 thereby d~ning the l~n~1sc~ring border or e~ging
Another system is to insert the blocks 1 in a substrate end to end
5 without using an edging 19, as shown in Figure 6b. Again, lower face 10 is
embedded in the substrate and upper face 9 and top 2 define the edging
above the substrate surface. Grooves 8 then form an interior conduit that
can receive pipes, conduit, electrical wiring, or function alone as a drainage
conduit.
Figure 6c discloses a third landscaping block system. The blocks 1
are inserted into substrate 40 end to end, thereby fixing the blocks 1 in the
substrate. ~lignmçnt of the blocks is m~int~ined by use of connectors or
coupling means 50 that connect the adjacent ends of the adjacent blocks.
For example, end 51 of block 60 is adjacent end 52 of block 61 and ends 51
15 and 52 are coupled by connector 50. The connectors can be tubing or a
narrow strip that ~t~n~s from the upper portions of adjacent grooves.
Also, a single elongated tubing may pass through groove 8 from end to end
the entire length of blocks.
The method of the present invention is shown generally in Figure 7.
20 First, the block-forming m~t~ri~l~7 typically water, cement, sand, and
aggregate, are mixed and transported to a block molding m~hine. A wide
variety of ~ lures are known to make blocks having various characteristics
- such as strength, water absorbtion, density, shTink~ge, and other factors
meeting ASTM standards and depending on the desired application of the
25 block. The ll~i~ e is l,lepared in any number of mixers known in the art.
The ll~i~lure is then placed in a hopper which transports the llli~ e to a
WO 95132083 PCT/US95/06166
- 20 -
21673~c~
block molding m~hine shown generally in Figure 8. Any block molding
m~c.hine known in the art`may be used. One m~chine found useful is the
V3-12 Vibrapac, made by Besser Colllp~l~, Alpena, Michigan.
The llli~ e or fill is then poured or loaded into mold 70 sitting on
5 or mated with generally planar steel pallet 71 as shown in Figure 9.
Specific aspects of the mold are discussed further below. The top of mold
70 is then scraped with a cut-off bar to remove excess llli~lule. Mold 70 is
then subjected to vertical compression by head 72 moving downward on top
of mold 70. Further details of head 72 are provided below. Head 72 acts to
10 compress the fill within mold 70 for a period of time sufficient to form a
solid, contiguous block. Generally, each block producing cycle has a
duration of six to twelve seconds at a total load of 1500 to 2000 pounds.
Additionally, mold 70 and horizontal platform 71 may be agitated during
compression.
Once the compression is complete, platform 71 is lowered vertically
away from mold 70 into a de-molding or stripped position and head 72
pushes the newly molded blocks dowllwd~d through mold 70 so that they
remain on platform 71. Head 72 is then raised vertically.
Once the blocks are formed, they are cured by various means known
20 in the art. Typically, blocks are cured in kilns for up to twenty-four hours
under pressure and/or with steam. Once cured, the blocks may be split.
Splittin~ methods such as hand-splitting with h~mmer and chisel, and
m~chine splitting are known in the art. Additional details of the splitter
used in connection with the present invention are provided below. After
25 splitting, the blocks are palletized or otherwise packaged for .~hipment or
storage.
wo ss/320s3 - 21 21 6 7 3 o ~ PCr/usg5/o6l66
The method of ~e present invention is more specifically directed to
molding landscaping block 1, having angled first end 6. In order to more
easily and efficiently make block 1, mold 70 and compression head 72 are
used. A top view of an embodiment of mold 70 is shown in Figure lOa.
S Mold 70 has a front vertical wall 73, generally opposed back vertical wall
74, and generally opposed side walls 75a, 75b ~lefining a generally
rect~n~ r, vertical outer wall or edge 76. Mold 70 further includes one or
more volumes 77 extending from the top 78 to the bottom 79 of mold 70.
Volume 77 is defined by a continuous vertical wall 80, described further
lO below. When mold 70 is placed on top of or mated with platform 71,
volume 77 is open at the top 78 of mold 70, but closed at the bottom 79 of
the mold by platform 71.
As shown in Figures 9 and lOa, block 1 is preferably molded
vertically, i.e., the end 6 to end 7 dimension of block 1 is positioned
15 vertically in mold 70 from top 78 to bottom 79. Vertical wall 80, which
delimits volume 77, defines the cross-sectional shape of block 1. Vertical
wall 80 includes a first pair of opposed sidewalls 8 la, 8 lb and second pair
of opposed sidewalls 82a, 82b.
Also as shown in Figure lOa, block 1 is ~lerelably formed in pairs.
20 For example, volume 83 in Figure lOa defines a composite block 84 which
comprises a first block 85 and second block 86 pair. Vertical wall 80 is
configured so that blocks 85, 86 are positioned top to top, i.e., top 2 of
- block 85 is parallel and connected to top 2 of block 86 at plane 89. As will
be discussed further below, composite block 84 is split along plane 89 to
25 form first block 85 and second block 86, each having a natural or split
surface ~ea~ ce at top 2. The first pair of opposed sidewalls 81a, 81b
WO 9S/32083 ~ - 22 - PCI/US95/06166
2167~
define bottom 3 of block 85 and bottom 3 of block 86, respectively. The
second pair of opposed sidewalls 82a, 82b define sides 4, 5 of block 85 and
sides 4, 5 of block 86.
When mold 70 is positioned in the molding position on platform 71,
S the second end 7 of blocks 85, 86, respectively, is defined by platform 71.
The first angled end 6 of blocks 85, 86 are formed at the top 78 of mold 70.
As shown in the front view of mold 70, Figure 11, the top 78 of mold 70
has a saw-tooth or serrated shape. The angle of each side 100, 101 of top
99 defines the angle of the first end of each block 77 in the four respective
10 rows 99 of mold 70.
In one embo~limçnt mold 70 is formed by a solid block of steel, for
example, with volume 77 m~hined out of the solid block.
In order to form angled end 6 on blocks 85, 86 in mold 70,
co~ ression means 72 includes a plurality of shoes 110, with each shoe
110 fitting over the top of each volume 77 to form angled end 6. The
general head 72 and shoe 110 configuration is shown in Figure 13.
As shown in Figure 14, the bottom 81 of each shoe 110 has an angle
complementary to the desired angle of first end 6 of each molded block 1.
Therefore, when head 72 is compressed downward into mold 70 and each
20 shoe 110 co~ lesses into each volume 77, there is equal pressure across
angled end 6, thereby forming a structurally sound angled end 6 on block 1.
As discussed above, block m~chines may include a cut-off bar to
scrape excess concrete offthe top 78 of mold 70 and bottom of shoes 110.
As shown in Figure 15, one embo~1iment of cut-offbar 111 has a serrated
25 bottom edge 113 with angles complçmçnt~ry to the top 78 of mold 70. In
another embo~imçnt cut-offbar 111 is generally rect~n~ r with planar
WO 9S/32083 2 1 6 7 ~ Q 5 rcT/usgs/06l66
- 23 -
top and bottom edges. In use, this embodiment would move up and down
following the collloul~ of the top 78 of mold 70 and shoes 110. In another
embo-limçnt cut-off bar 111 may have flexible top and bottom edges.
In an ~ltern~te embo-liment volumes 77 in mold 70 are rotated
5 ninety degrees, as shown in Figure 10b. The angles on shoes 110 are also
rotated ninety degrees to retain the same angled ends 6 on block 1. Cut-off
bar 111 would then be generally rect~n~ r and move vertically as it
passes over the top 78 of mold 70 to perform its scraping function.
Once composite block 84 is formed using mold 70 and head 72
10 described above, it is cured. After curing, block 84 is split. Figure 16
generally shows a splitter 115 that can be used with the present invention.
A top blade 116 and bottom blade 117 are used to split block 84 along the
desired plane 89.
Since composite block 84 is molded having a top angled end, top
lS blade 116 is serrated with angles that are complement~ry to the angled end
of composite block 84. Since the bottom of composite block 84 is flat,
bottom blade 117 is straight. When composite block 84 is positioned in
splitter l lS so that blades 116 and 117 are co-planar with plane 89, bottom
blade 117 is forced upward and top blade 116 is forced downward, thereby
20 applying generally equal pressure along plane 89 to split block 84 into
blocks 85 and 86.
Additionally, as shown in Figure 10, sidewalls 82a, 82b may include
v-shaped grooves 130a, 130b, respectively, that assists in providing a clean
split along plane 89. Further, a v-shaped groove 131 can be provided at the
25 end of composite block 84 rlçfining ends 6 of blocks 85 and 86 to assist in
providing a straight split at plane 89. Mold 70 in Figure 10a is configured
WO 9S132083 ~ PCIIUS95/06166
- - 24 -
21673~
so that when composite block 84 is split into separate blocks, the splitting
process does not force adjacent blocks away from each other, thereby
requiring additional h~ntlling or processing of the blocks. Referring to
Figure lOa, when the first line of composite blocks, id~ntified as blocks A
S through D, are split, the angled end 6 on blocks A and D slopes downward
toward walls 75a and 75b respectively. Therefore, blocks A and D do not
fall away from blocks B and C.
In the embodiment of mold 70 shown in Figures 9 and 10, twelve
pairs of blocks 1 are formed with each pair having a block 1 with an angled
10 end 6 complementary to the angled end 6 ofthe other block 1 of the pair,
yielding twenty-four blocks per cycle. In a typical set-up, six to ten
molding cycles may be completed per minute.
Mold 70 need not form block 1 in pairs. Figure 17 shows an
~ltern~te mold 120 where each volume 121 defines the cross-sectional
15 shape of a single block 1. In this embodiment splitter 115 is not required.
The above discussion provides various examples and embodiments
of the invention and are not intended to limit the scope of the invention.
