Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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INSERT APPARATUS FOR A MOLD, METHOD OF MANUFACTURING A
CONCRETE UNIT, METHOD OF INSTALLING A WALL AND
METHOD OF RETROFITTING AN EXISTING MOLD
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates generally to apparatus and methods for
manufacturing
structural units, such as concrete blocks, brick, clay-based material, payers,
segmental
retaining walls (SRWs), etc., from a mold and, in particular, to an insert
apparatus for use in
connection with a mold for manufacturing a concrete unit, a method of
manufacturing a
concrete unit having a design or indicia applied on a side or sides of the
unit, a method of
installing a plurality of concrete units as a wall surface and a method of
retrofitting an
existing mold for manufacturing a concrete unit having a design or indicia
applied on a side
thereof.
Description of Related Art
[0002] In the field of manufacturing concrete units, such as concrete,
concrete blocks,
payers, bricks, SRWs and the like, a mold is required. In operation, a
conveyor or similar
transport mechanism moves a pallet or plate underneath the mold, which
typically includes an
open top, open bottom and multiple inner cavities for forming the concrete
unit. After the
pallet or plate has moved into engagement with the underside of the mold, a
fill drawer
moves over the open top of the mold and places material, such as concrete or
cement, into the
inner cavity portion of the mold. Next, a machine head or plunger compresses
the material,
thereby providing additional compaction of the concrete material in the mold.
Typically, the
mold is vibrated while the concrete material is being placed or injected
therein to provide
better settling and uniformity.
[0003] After the concrete material is molded or shaped within the inner cavity
of the mold,
the pallet or plate moves down in a vertical manner away from the bottom of
the mold and
the compacted, consolidated and condensed concrete units also move down with
the pallet.
Typically, the concrete units are further cured, such as by natural curing, or
by some other
catalytic means. In this manner, a concrete unit is manufactured.
[0004] Concrete units, such as blocks, are now being used extensively in both
consumer
and construction situations. For example, a consumer may now wish to build his
or her own
retaining wall or decorative wall on their property. Accordingly, a need has
arisen for more
functional, decorative and/or aesthetically pleasing concrete units.
Therefore, in order to
manufacture such specialized units, typically the mold must be modified to
apply a design
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surface. There are different processes for accomplishing a decorative or
roughened surface,
with the two typical processes being either roughening the surface as the unit
is dropped
down through the mold or mechanically impressing a design or indicia using
complicated
mechanical devices or a labor-intensive single mold apparatus.
[0005] One drawback to applying a design or other indicia on a concrete unit
is the
limitation of how a concrete unit is manufactured by the mold. As discussed
above, the
bottom or plate moves to bound the mold and allow concrete material to be
placed therein,
and when this material is consolidated/compacted/condensed (CCC), the pallet
or plate
moves away from the bottom of the mold in a vertical direction. Therefore, any
design that is
placed upon a vertical surface of the concrete unit would be removed or
otherwise distorted
as the CCC concrete unit drops and slides down through the mold via the
pallet. However,
this does not pose an insurmountable problem when merely producing concrete
units with a
roughened surface. Since the design is not specific and only a roughened
surface is desired,
systems and processes have been developed for applying such a roughened
surface to a unit.
For example, see U.S. Patent Nos.: 6,464,199 to Johnson; 6,209,848 to Bolles
et al.;
6,138,983 to Sievert; 6,113,379 to LaCroix et al.; 5,217,630 to Sayles; and
5,879,603 to
Sievert. See also Patent Application Publication No. U.S. 2001/0007380 to
LaCroix et al.
However, such processes and molds are deficient in that only a roughened or
textured surface
can be applied to the vertical face of the unit. Therefore, such systems and
processes are not
capable of producing a specified design or indicia, which would not be removed
or distorted
as the CCC concrete unit is discharged from the mold.
[0006] Other processes have been developed for placing decorative surfaces,
designs and
indicia on a vertical face of a concrete unit. For example, see U.S. Patent
Nos.: 5,817,249 to
Forlini; 2,532,049 to Wittke; 1,693,693 to Dexter; and 1,635,093 to McPherson
et al.
However, these molds and processes are quite complicated. The mold must be
specifically
designed to create the design or indicia and typically a wall of the mold must
be pressed in
toward the concrete material and then removed prior to dropping the unit from
the mold. In
addition, such intricate molds and machines are expensive and labor intensive,
since multiple
parts and walls and other mechanisms must be utilized to apply the indicia,
remove the design
portions and allow the block to be removed from the mold. Further, such molds
and
processes may not be well suited for the mass production of concrete units.
SUMMARY OF THE INVENTION
[0007] It is, therefore, an object of the present invention to provide an
insert apparatus, a
method of manufacturing and a method of retrofitting a mold for manufacturing
a structural
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unit that overcomes the deficiencies of the prior art. It is another object of
the present
invention to provide an insert apparatus and methods of manufacturing a
structural unit
having a design, indicia, projection or recess on one or more vertical
surfaces of the unit. It is
yet another object of the present invention to provide an insert apparatus and
methods of
manufacturing a structural unit that changes the general dimensions of the
unit. It is a still
further object of the present invention to provide an insert apparatus for use
in connection
with a mold for manufacturing a structural unit that is simple in its use and
does not remove
or otherwise distort the applied design when the unit is removed from the
mold. It is another
object of the present invention to provide a method of manufacturing a
structural unit having
a design or indicia impressed or recessed upon a vertical side or sides of the
unit that is more
efficient and capable of mass manufacturing such units. It is a still further
object of the
present invention to provide a method of retrofitting an existing mold, such
that a structural
unit can be produced having a design, indicia, projection or recess thereon.
[0008] The present invention is directed to an insert apparatus for a mold for
manufacturing at least one structural unit. The insert apparatus includes a
Garner configured
to operatively engage the mold. The insert apparatus also includes a face
having design
portions and in operative communication with the carrier portion. The design
portions extend
into or out of an inner cavity of the mold.
[0009] The present invention is also directed to a method of manufacturing a
structural unit
having a design or indicia applied on at least one side of the unit. The
method includes the
steps of: (a) engaging a Garner within a mold, where the carrier is in
operative
communication with a face having design portions extending into or out of an
inner cavity in
a mold; (b) placing a material into the inner cavity of the mold, such that
one or more sides of
the inner cavity comprise the face portion; (c) at least one of consolidating,
compacting and
condensing the material, thereby forming the structural unit; and (d) removing
the structural
unit from the mold.
[0010] The present invention is also directed to installing a plurality of
structural units as a
wall. This method includes the steps of: providing multiple structural units,
where some or
all of these units include a design portion extending from and/or recessed
within a face
surface of the structural unit; successively applying mortar to a surface of
the structural unit
and positioning a successive structural unit on the mortared surface, thereby
forming the wall
with a wall surface having a desired master design thereon; and applying
additional mortar to
at least one mortar joint between at least two structural units, the
additional mortar effectively
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joining the design portions between the at least two structural units, thereby
providing a more
complete desired master design on the wall surface.
[0011] The present invention is further directed to a method of retrofitting
an existing mold
for manufacturing a structural unit having a design or indicia applied on at
least one side of
the unit. The mold includes an inner cavity with one or more sides comprising
the plate
element removably attached to the side. The method includes the steps of: (a)
detaching and
removing the plate element from the side of the inner cavity of the mold; (b)
providing an
insert apparatus including a carrier in operative communication with a face
having design
portions; and (c) engaging the carrier in place of the removed plate element,
wherein the
design portions of the face portion extend into or out of the inner cavity of
the mold.
[0012] The present invention is also directed to an improvement for use in
connection with
a mold for manufacturing a structural unit having a design applied on at least
one side of the
unit. The improvement comprises an insert. This insert is configured to
operatively engage a
portion of the mold. The insert comprises a carrier having a face portion with
at least one
design portion extending into or out of the inner cavity of the mold.
[0013] The present invention is also directed to an insert for a mold for
manufacturing at
least one structural unit. The insert includes a carrier configured to
operatively engage a
portion of the mold. In addition, the carrier includes a face portion with at
least one design
portion extending into or out of the inner cavity of the mold.
[0014] The present invention, both as to its construction and its method of
operation,
together with the additional objects and advantages thereof, will best be
understood from the
following description of exemplary embodiments when read in connection with
the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Fig. 1 is a perspective view of an insert apparatus according to the
present
invention;
[0016] Fig. 2 is an edge view of the insert apparatus of Fig. 1;
[0017] Fig. 3 is an edge view of a further embodiment of an insert apparatus
according to
the present invention;
[0018] Fig. 4 is a schematic view of an insert apparatus according to the
present invention;
[0019] Fig. 5 is an edge view of a further embodiment of an insert apparatus
according to
the present invention;
[0020] Fig. 6 is a front view of a modified plate element for use in
connection with a mold
according to the present invention;
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[0021] Fig. 7 is a perspective and exploded view of a further embodiment of an
insert
apparatus according to the present invention;
[0022] Fig. 8 is a top view of a mold according to the prior art;
[0023] Fig. 9 is a schematic view of the insertion of an insert apparatus
according to the
present invention in a mold;
[0024] Fig. 10 is a schematic view of the installation of multiple modified
structural units
according to the present invention;
[0025] Fig. 11 is a front view of a portion of a wall constructed using the
modified
structural units made in accordance with the methods of the present invention;
and
[0026] Fig. 12 is a detailed front view of a further embodiment of a wall
built with
structural units using the methods according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] For purposes of the description hereinafter, the terms "upper",
"lower", "right",
"left", "vertical", "horizontal", "top", "bottom", "lateral" and derivatives
thereof shall relate
to the invention as it is oriented in the drawing figures. However, it is to
be understood that
the invention may assume various alternative variations and step sequences,
except where
expressly specified to the contrary. It is also to be understood that the
specific devices and
processes illustrated in the attached drawings, and described in the following
specification,
are simply exemplary embodiments of the invention. Hence, specific dimensions
and other
physical characteristics related to the embodiments disclosed herein are not
to be considered
as limiting.
[0028] The present invention is directed to an insert apparatus 10, as shown
in various
embodiments in Figs. 1-3, S and 7, a method of manufacturing a structural unit
100, a method
of installing a plurality of structural units 100 as a wall surface 103 and a
method of
retrofitting an existing mold 110 for manufacturing such a structural unit
100. As discussed
in detail hereinafter, the insert apparatus 10 is particularly effective for
use in connection with
the mold 110, where the mold 110 is used for manufacturing at least one and
typically
multiple structural units 100, such as concrete units, as illustrated in Figs.
10-12. The
structural unit 100 may be a concrete block, a cinder block, a cement block, a
brick, a clay-
base unit, a payer, a segmental retaining wall unit, etc. In addition, the
mold 110 includes an
inner cavity 112, which is adapted to receive a typically liquid and
thereafter curable
material, such as cement, concrete, aggregate or similar materials.
[0029] In one preferred and non-limiting embodiment, the insert apparatus 10
is for use in
connection with the mold 110 for manufacturing one or more structural units
100. In
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particular, the insert apparatus 10 includes a carrier 12 that is adapted to
operatively engage a
portion or part of the mold 110. Further, the insert apparatus 10 includes a
face 14, and this
face 14 includes one or more design portions 16 thereon. In addition, the face
14 is in
operative communication or engagement with the carrier 12. The design portions
16 extend
into or out of the inner cavity 112 of the mold 110.
[0030] As best seen in Figs. 1-3, S and 7, the face 14 is connected or
attached to the carrier
12, and the design portions 16 create a design or indicia that is unprintable
(that is impressed
or recessed) upon the surface of a structural unit 100. Further, the design
portions 16 create
this design or indicia on typically a vertical surface of the structural unit
100. While the
design portions 16 shown in the various figures of the present application
constitute only
some shapes or designs, any number of shapes, designs, indicia or other
desired faces can be
obtained using the insert apparatus 10 and the methods discussed hereinafter.
For example,
functional impressions or recesses can be formed on the structural unit 100 to
produce
interlocking units, architectural units or other structural units having
similar functional
characteristics. Dimensionally, the face 14, and in particular the design
portion 20, may
produce impressions, recesses or a combination of impressions and recesses on
the surface of
a structural unit 100.
[0031] In another embodiment, the Garner 12 and the face 14 may be constructed
or
manufactured as an integral piece. This may be particularly useful in an
application where
different patterns are not required, and the same insert apparatus 10 can be
used in connection
with the same mold 110 throughout the process. In this embodiment, the carrier
12, face 14
and design portions 16 are an integral unit.
[0032] In a further embodiment, and as illustrated in Fig. 3, the face 14 may
be removably
attachable to the carrier 12, and for example, the carrier 12 may be in the
form of a
substantially T-shaped structure. Accordingly, and in this embodiment, the
carrier 12 would
have a horizontal wall 18, a vertical wall 20, a first side surface 22, a
second side surface 24,
a first edge surface 26 and a second edge surface 28. Therefore, multiple
faces 14 can be
used in connection with such a carrier 12. A first face 14 could be removably
attached to the
first side surface 22 of the vertical wall 20, and a second face 14 could be
removably attached
to the second side surface 24 of the vertical wall 20. In this manner, while
multiple structural
units 100 are being formed, each structural unit 100 can have a different
design or indicia
applied thereto.
[0033] As discussed above, the face 14 may be removably attachable to the
Garner 12.
Therefore, a removable attaching means 30 facilitates the releasably
attachable functionality
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of either one or both of the face surfaces 14 with respect to the Garner 12.
In particular, the
face 14 would be removably attachable to either the first side surface 22
and/or the second
side surface 24. Specifically, it is the removable attaching means 30 that
allows the face 14
to engage the carrier 12 in a removable and non-permanent manner. Any
removable
attaching means 30 is envisioned, such as an attachment device, an adhesive
compound,
interacting magnetic elements, a flange and groove arrangement, a male/female
plug
arrangement, an elongated member in operative communication with the carrier
12 and a face
14, a clamp, etc.
[0034] In one preferred and non-limiting embodiment, one or more pins 32 could
be
provided as the removable attaching means 30. These pins 32 could be
insertable through
corresponding pin orifices 34 on the Garner 12, and further and aligned pin
orifices 36 on the
face 14. As shown in Fig. 7, the face 14 would be placed against the first
side surface 22
and/or the second side surface 24, and the pins 32 would be inserted through
the pin orifices
34 on the Garner 12 and further into the pin orifices 36 on the face 14. These
pins 32 would
allow the face 14 to be attached to the Garner 12 throughout the process, yet
allow the pins 32
to be removed, thereby releasing the face 14 from the carrier 12. Thereafter,
a different face
14 could be used in connection with the same carrier 12.
[0035] A mold 110 according to the prior art is illustrated in Fig. 8. This
mold is a typical
box-like structure, including a first side wall 114, a second side wall 116, a
first end wall 118
and a second end wall 120. It is the first side wall 114, the second side wall
116, the first end
wall 118 and the second end wall 120 that create the box that is the mold 110.
However, the
concrete material or similar material is not simply placed into the mold 110.
Instead, with
respect to the inner surfaces of the walls (114, 116, 118, 120), a side plate
element 122 is
secured to an inner surface of the first side wall 114 and the second side
wall 116. Similarly,
a plurality of end plate elements 124 are arranged on the inner surfaces of
the first end wall
118 and the second end wall 120.
(0036] It should be noted that this arrangement is for constructing two
structural units 100,
and any number of side plate elements 122 and end plate elements 124, when
used in
connection with variously sized and shaped molds 110, will provide for the
manufacture of
one or multiple variously sized and shaped structural units 100. In the
present embodiment,
the end plate elements 124 are secured to the first end wall 118 and the
second end wall 120
in such a way that each end plate element 124 includes a first end that abuts
a side plate
element 122 and a free end, which forms a groove 126. In addition, the mold
110 may
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include one or more structural unit cavity forms 128, which assists in forming
cavities in the
structural unit 100 after the material is injected into the inner cavity 112
of the mold 110.
[0037] Returning to the insert apparatus 10, the Garner 12 may include a
projection 38 or a
groove 40 on a surface of the Garner 12. This projection 38 and/or groove 40
is adapted to
mate with a complimentary projection 42 or groove 44 located on a surface
within the inner
cavity 112 of the mold 110. For example, as seen in Fig. 3, a projection 38
(acting as a
flange) may be disposed on the first edge surface 26 and/or the second edge
surface 28 of the
carrier 12. The projection 38 is configured to mate with the groove 44, which,
in this
embodiment, is identical to the groove 126 discussed above in connection with
the mold 110.
Similarly, as shown in Figs. 5-7, the groove 40 may be located on the carrier
12, and
specifically the first edge surface 26 and/or the second edge surface 28, and
this groove 40 is
configured to mate with a projection 42 in the inner cavity.
[0038] In one preferred and non-limiting embodiment, and as illustrated in
Figs. 5-7, the
groove 40 on the carrier 12 is in the form of an upside-down hemi-pyramidal
groove, and the
projection 42 of the mold 110 is in the form of a complimentary upside-down
hemi-
pyramidal projection 42. As seen in Fig. 6, a modified end plate 130 may be
provided, and
this modified end plate 130 would include the projection 42, which interacts
with and
fractionally engages the groove 40 on the first edge surface 26 and/or the
second edge surface
28 of the Garner 12. In addition, any number of shapes and sizes of
projections 38 and
grooves 40 on the carrier 12, and complimentary projections 42 and grooves 44
on the mold
110 are envisioned. Further, any manner of attaching the insert apparatus 10
within the mold
110 is also envisioned.
[0039] The carrier 12 may be manufactured from a variety of materials, for
example, the
carrier 12 may be manufactured from a thermoplastic material, a synthetic
material, a plastic,
a polymer, wood, a rigid material, etc. Similarly, the face 14 may be
manufactured from a
variety of materials. For example, the face may be manufactured from a
thermoplastic
material, a synthetic material, a plastic, a polymer, wood, a rigid material,
a flexible material,
a foam, a closed-cell foam, etc. In one preferred and non-limiting embodiment,
the face 14 is
manufactured from a closed-cell polymeric material.
[0040] It is envisioned that a different design portion 16 is disposed upon
the face surface
46 of a plurality of faces 14, and each different design portion 16, when
produced in a line,
create a desired master design 48. For example, see Figs. 10-12. These
different design
portions 16, and/or the desired master design 48 may be disposed upon the face
surfaces 46
of the faces 14 by an automated process. In particular, the automated process
may include
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the steps o~ storing the desired master design 48 on a computing device;
positioning a face
substrate in operative communication with an etching device, which is in
communication
with the computing device; and etching, by the etching device, the stored
desired master
design 48 on the face substrate. Next, the face substrate would be cut into a
set of
predetermined sized and shaped faces 14 for use in connection with the Garner
12. Therefore,
as seen in Figs. 10-12, multiple structural units 100 manufactured in
accordance with the
present invention can be assembled into a wall 102 (as discussed in detail
hereinafter),
thereby creating the desired master design 48 on the wall surface 103.
[0041] In operation, and according to the present method of manufacturing a
structural unit
100, the carrier 12 is engaged within the mold 110. Further, the carrier 12
already includes or
is in operative engagement with one or more faces 14. As seen in Fig. 9 and as
occurs in a
typical process, a pallet 140 is placed on a conveyor 142, and the conveyor
142 transports the
pallet 140 to a position directly underneath the mold 110. However, according
to the present
invention, the insert apparatus 10 is specifically positioned with respect to
the mold 110, such
that when the pallet 140 is moved up toward the mold 110, thereby forming a
bottom surface
of the mold 110, the insert apparatus 10 is appropriately engaged within the
mold 110. When
the insert apparatus 10 is constructed as illustrated in Fig. 3, where the
carrier 12 includes
projections 38, the insert apparatus 10 is positioned such that these
projections 38 engage the
grooves 126 of the mold 110 when the pallet 140 is engaged with the mold 110.
After the
pallet 140 is engaged, and the insert apparatus 10 is in place, the concrete,
cement, or similar
material is placed into the inner cavity 112 of the mold 110, as schematically
illustrated by
arrow A in Fig. 9.
[0042] It is envisioned that, according to the prior art and typical
processes, a block
machine (not shown) can be used to compact and assist in forming a structural
unit 100 after
the concrete or similar material has been placed into the inner cavity 112 of
the mold 110.
Similarly, a vibration apparatus may also be used to help in settling,
consolidating,
compacting and condensing the material, as is known in the art. After the
insert apparatus 10
is placed in the mold 110, the process according to the prior art proceeds
accordingly. After
the concrete unit is consolidated, compacted and condensed, the pallet 140 is
vertically
dropped down, carrying with it the newly-formed structural unit 100, having a
design portion
104 disposed thereon. It is envisioned, at this point, that the structural
unit 100 will be
dropped down together with the insert apparatus 10, which is still adhered to
or attached to
the structural unit 100 or units. It is envisioned that the carrier 12 may be
removed
mechanically (or by hand) from the insert apparatus 10 at this point in the
process or at some
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later point. Further, the face 14 may be disengaged from the Garner 12 and a
new face 14
replaced thereon. In addition, the structural unit 100 may be further cured
before subsequent
use and the face 14 may be removed at this point.
[0043] It is often necessary for the insert apparatus 10 to be removably
engaged with the
mold 110 for effective creation of the structural unit 100. Therefore, it is
also envisioned that
one or multiple modified end plates 130, as discussed above, can be introduced
at any one or
more locations within the mold 110. Due to the shape of the projection 42 on
the modified
end plate 130, and the complimentary groove 40 on the carrier 12 (see Figs. 5
and 6), the
upside-down hemi-pyramidal shape maximizes the centering capability as the
pallet 140 lifts
the insert apparatus 10 up into the mold 110. Specifically, due to the shape
of the projection
42 on the modified end plate 130, the insert apparatus 10 would have some room
for error in
the initial positioning, and this error would be overcome and the insert
apparatus 10 engaged
within the mold 110 upon complete engagement. Any number of shapes and
projections to
achieve such centering and alignment capabilities are envisioned. In one
preferred
embodiment, the face 14 and the design portion 16 are manufactured from a foam
material.
The foam material would be particularly suitable to this process, since such a
material would
not bind with the concrete or similar material as it cures. However, any
material of
construction of the insert apparatus 10 is envisioned. Further, while the mold
110 of Fig. 8
has been shown and described, any number of molds 110 can be used. In
addition, the insert
apparatus 10 may be top loaded or bottom loaded (as described) according to
the user and the
arrangement of the equipment in the process.
[0044] In another aspect of the present invention, a presently existing mold
110 may also
be retrofitted for forming the desired structural units 100. For example, the
insert apparatus
10, the carrier 12 and/or the face 14 can take the place of any one or more of
the side plate
elements 122 and the end plate elements 124. Further, any vertical surface
that is removable
and replaceable, may be replaced with an appropriately sized and shaped insert
apparatus 10,
Garner 12 andlor face 14 for forming a design or indicia on any one or more of
the vertical
faces of the structural unit 100. Due to the easy engagement and appropriate
size of the insert
apparatus 10, the present invention is particularly adaptable to suit any of a
variety of design
considerations and options: This provides the user with the maximum amount of
flexibility
in choosing the designs to satisfy a consumer's needs. Therefore, the present
invention is
useful in both mass production of structural units 100, as well as special
order units.
[0045] As discussed above, the insert apparatus 10 may be formed as an
integral insert
including the carrier 12 and the face 14. In this preferred and non-limiting
embodiment, the
to
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carrier 12 would engage at least a portion of the mold 110, and the Garner 12
would include
the face 14 as a face portion or integral portion of the Garner 12. As
discussed above, the
face 14 would include one or more design portions 16 extending into or out of
the inner
cavity 112 of the mold 110. Accordingly, this integrated carrier 12 and face
14 (with design
portions 16) could be engaged with and fit into a pre-existing mold 110 for
use in
constructing the structural unit 100, as discussed in detail above.
[0046] Turning now to the method of installing a plurality of structural units
100, a step in
the method and various end results are illustrated in Figs. 10-12. In this
method, the
structural units 100 having the structural unit design portions 104 disposed
thereon are
manufactured in accordance with the methods discussed above. Any one or more
of the
structural units 100 may include the design portions 104. In installation,
mortar 106 is
applied to a surface of the structural unit 100, typically at the top surface
and/or the bottom
surface, and a successive structural unit 100 is placed on this mortar
surface, thereby
eventually forming the wall 102 with the wall surface 103 having the above-
discussed desired
master design 48 disposed thereon. In addition, in order to provide a more
complete desired
master design 48, additional mortar 106 is placed on portions of a mortar
joint 108 between
two structural units 100. The mortar 106 that is placed in these mortar joints
108 joins the
design portions 104 of adjacent structural units 100 and completes a more
detailed desired
master design 48. This desired master design 48 would not include gaps in the
design due to
the requirement of having these mortar joints 108.
[0047] A different design portion 104 may be disposed upon the face surface of
the
structural units 100, and each different design portion 104, when arranged and
aligned to a
predetermined position, create the desired master design 48. In this manner, a
projecting or
relief design may be formed on the wall surface 103 of the wall 102. The wall
102 may be a
retaining wall, a structural wall, a room wall, an architectural wall, an
aesthetic wall, etc.
[0048] In this manner, an insert apparatus 10 is provided for forming a design
or indicia
upon one or more vertical faces of the structural unit 100, typically a
concrete or cement unit.
In addition, the present invention provides a method of manufacturing a
structural unit 100
having a design portion 104 on the structural unit 100, and this process is
adaptable, flexible
and more simple in operation than the prior art processes. Still further, the
present invention
provides a method of retrofitting an existing mold 110 for manufacturing such
structural units
100. During the typical bottom loading and unloading process, the design or
indicia formed
on the structural unit 100 would not be removed or distorted in any way, since
the insert
apparatus 10 is ejected along with the structure 100. Further, the insert
apparatus 10 does not
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CA 02533351 2006-O1-19
WO 2005/012666 PCT/US2004/024018
use complicated machinery and extensive labor to successfully employ. Also
provided is a
method of installing a plurality of structural units 100 as a wall 102 having
a wall surface
103. When built in accordance with this method, a desired master design 48 is
displayed, and
this method provides new and unexpected results in the fields of masonry and
design
architecture.
[0049] This invention has been described with reference to the preferred
embodiments.
Obvious modifications and alterations will occur to others upon reading and
understanding
the preceding detailed description. It is intended that the invention be
construed as including
all such modifications and alterations.
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