MASONRY BLOCKS HAVING A PLURALITY OF FACING MATERIALS AND MASONRY BLOCK MANUFACTURING

Description

TECHNICAL FIELD

This document describes devices, systems, and methods related to masonry blocks and masonry block manufacturing.

BACKGROUND

Masonry blocks are used in various applications, and can be manufactured with different surfaces and positioned to form retaining walls of different sizes, configurations, and aesthetics. Masonry blocks can be manufactured using various materials having selected aesthetic and structural characteristics.

SUMMARY

In some aspects, the techniques described herein relate to a block including: a front surface; a second surface adjacent the front surface; and a side surface adjacent the front surface; wherein: the front surface consists of a first material; the side surface consists of the first material; and the second surface includes: a first area adjacent to the front surface and consisting of the first material; a second area adjacent to the side surface and consisting of the first material; and a third area consisting of a second material; the first material and the second material having different visual appearances.

In some aspects, the techniques described herein relate to a block, wherein the first area is adjacent to the second area.

In some aspects, the techniques described herein relate to a block, wherein: the block further includes a fourth surface on a fourth side opposite of the second surface; and the fourth surface includes: a fourth area adjacent to the front surface and consisting of the first material; a fifth area adjacent to the side surface and consisting of the first material; and a sixth area consisting of the second material.

In some aspects, the techniques described herein relate to a block, wherein the first material is a display material and the second material is a hidden material.

In some aspects, the techniques described herein relate to a block, wherein the first material forms less than 50% of an overall weight of the block.

In some aspects, the techniques described herein relate to a block, wherein the first material includes i) the second material and ii) a colorant.

In some aspects, the techniques described herein relate to a block, wherein: the second material includes at least one of the group consisting of i) concrete and ii) stone mixture; and the colorant includes at least one of the group consisting of i) a dry pigment powder, ii) a liquid suspension of the dry pigment powder, iii) a liquid dye, and iv) mineral aggregate.

In some aspects, the techniques described herein relate to a block, wherein the second material is a first concrete, and the first material is a curing material different than the first concrete.

In some aspects, the techniques described herein relate to a block, wherein the curing material different than the first concrete is a cement free of mineral aggregate.

In some aspects, the techniques described herein relate to a block, wherein the block further includes at least one lug.

In some aspects, the techniques described herein relate to a block, wherein the lug extends from the second surface and consists of the second material.

In some aspects, the techniques described herein relate to a block, wherein the lug includes the first material.

In some aspects, the techniques described herein relate to a method of manufacturing a block, the method including: depositing a first portion of a first material into a first-target location in a block mold; depositing a second portion of a second material into a second-target location in the block mold; depositing a third portion of the first material on top of both the first portion and the second portion.

In some aspects, the techniques described herein relate to a method, the method further including: storing for a predetermined amount of time; and demolding a block of the first material and the second material.

In some aspects, the techniques described herein relate to a method, wherein the block includes: a front surface; a second surface adjacent the front surface; and a side surface adjacent the front surface; wherein: the front surface consists of a first material; the side surface consists of the first material; and the second surface includes: a first area adjacent to the front surface and consisting of the first material; a second area adjacent to the side surface and consisting of the first material; and a third area consisting of a second material; the first material and the second material having different visual appearances.

In some aspects, the techniques described herein relate to a method, the method further including applying compaction to the second portion to urge, into a lug-portion of the mold, the second material.

In some aspects, the techniques described herein relate to a method, the method further including applying compaction to the third portion to urge, into a lug-portion of the mold, the second material.

In some aspects, the techniques described herein relate to a method, wherein the compaction further urges, into the lug-portion of the mold, the first material.

In some aspects, the techniques described herein relate to a method, the method further including applying compaction, the compaction including at least one of the group including i) vibrating, ii) tamping, and iii) impacting.

In some aspects, the techniques described herein relate to a method, the method further including: depositing, into a second block mold, the first material and the second material; depositing, into a third block mold, the first material and the second material; depositing, into a fourth block mold, the first material and the second material.

In some aspects, the techniques described herein relate to a method, wherein the block mold and the second block mold include lug-portions at offset locations; and the third block mold and fourth block mold include lug-portions at offset locations.

In some aspects, the techniques described herein relate to a method, the method further including loading, into a single shipping container a first block and a second block arranged with interlacing lugs; and loading, into the single shipping container, a third block and a fourth block arranged with interlacing lugs.

The devices, system, and techniques described herein may provide one or more of the following advantages. For example, this document describes masonry blocks that are composed of multiple material mixes—a first having a first set of characteristics (e.g., a relatively inexpensive material, having particular structural characteristic, and/or configured to be visible only from hidden faces in use) and a second having a second set of characteristics (e.g., having particular colored or aesthetic characteristics and/or more aesthetically desirable material used for faces configured to be visible in use). When assembled into a wall or other assembly, the masonry blocks can be oriented so that the aesthetically desirable material is visible, while costs may be saved by use of the hidden, low-cost material on portions of the block that are not visible. In some examples, the blocks include at least two sides define by a first material having aesthetically desirable material. The two sides can be adjacent major faces such that the block can be positioned at a corner location of a wall assembly and both visible faces are defined by the aesthetically desirable material.

In some cases, the hidden material may, in addition to or as an alternative to lower manufacturing costs, provide different mechanical properties compared to the aesthetically desirable material. For example, a display material may include aggregates, voids, textures or other surface features that enhance aesthetic characteristics, while the hidden material enhances robustness and structural strength of the finished block. In some examples, the finished block has a combination of aesthetic characteristics (e.g., by using a display material selected for a particular application) and structural characteristics suitable for a range of retaining wall and/or other applications.

Additionally, in some example embodiments, the blocks and manufacturing techniques described herein can facilitate efficient manufacturing. Multiple types of material mixes having different characteristics can be efficiently loaded into a mold to provide a block having surfaces and/or regions of different characteristics. For example, multiple materials can be sequentially loaded into a mold (e.g., without the use of stencils or dividers), while providing a block having regions of the respective material mixes (e.g., unmixed with one another). In some embodiments, such techniques can be used to facilitate manufacturing of a block having one or more, two or more, three or more, or more than four sides having a first visible characteristic that is different than visible characteristics of one or more other sides of the finished block. For example, first and second sides configured to be visible in a finished installation (e.g., retaining wall) can be efficiently manufactured to have a first visible characteristic, and one or more other sides configured to be hidden in the finished installation can have a second visible characteristic different from the first visible characteristic. Moreover, such blocks can be efficiently manufactured with a high throughput.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIGS. 1A and 1B are perspective views of an example block.

FIG. 2 is a side view of the example block of FIG. 1.

FIG. 3 is a top view of the example block of FIG. 1.

FIG. 4 is a side view of an example block.

FIG. 5 is a perspective view of an example block mold.

FIG. 6 is a schematic view of an example manufacturing process.

FIGS. 7A and 7B are a top views of example blocks having alternating lug locations.

FIGS. 8A-8H show operations of filling masonry block molds.

FIG. 9 shows example of computing devices.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Masonry blocks are described in this document that include first and second material mixes. For example, masonry blocks are described that include an aesthetic display material on certain surfaces (e.g., visible in an installed assembly, such as a retaining wall) and other surfaces having a hidden material (e.g., hidden and/or visible on surfaces configured to be hidden in the installed assembly). In some embodiments, a common fill or hidden material can be used across a range of blocks, while a display material can be customized and selected to have particular aesthetic materials on surfaces expected to be visible. In some embodiments, the hidden material is selected to have a relatively low cost and/or preferable mechanical or chemical properties. For example, a block may use a concrete—with tensile-improving aggregate or fiber—for a hidden material while also using an aggregate-free and/or died cement with a different surface finish on facing surfaces. Then, these blocks can be assembled (e.g., into a retaining wall) such that the facing surfaces having the display material are visible. In some embodiments, such configurations can facilitate an assembly with desired visual properties associated with the display material, while having lower costs and/or suitable structural properties associated with the hidden material.

In various example embodiments, blocks can be manufactured that are particularly suitable for use in retaining wall configurations in which two or more sides of the block are visible. For example, when positioned at a corner location of a wall, a front major face and an end face of the block are visible in the installed wall. Each of the front major face and the end face of the block are defined by a display material having desired aesthetic characteristics, while other portions and/or faces of the block are defined by a different material.

This document describes the manufacturing of blocks made of two or more material mixes. For example, one or more molds may be loaded in an iterative process that places a first material (e.g., the display material) in selected locations to ensure the first material is visible on visible facing surfaces in an installation (e.g., front major surface, side surface, etc.), while the hidden material is used on other regions and/or faces of a block that are not exposed in the installation.

In an example embodiment, the block includes alignment lugs. Such lugs can be configured to facilitate efficient block molding, packaging and handling, and/or alignment during installation. For example, blocks can be provided with lug arrangements that allow for effective packing patterns. This effective packing pattern can reduce wasted volume when blocks are loaded for shipping or storage, for example. In some cases, compaction can be applied to the contents of the molds (e.g., including via a colored display material) to urge the material of the blocks into the lug. Such configurations thus facilitate effective lug formation in a bock having desired aesthetic characteristics.

FIGS. 1A and 1B are perspective views of an example block 100. FIG. 1A shows the block 100 in wireframe, with hidden features shown. FIG. 1B shows the same block 100 with hidden features hidden. FIG. 2 is a side view of the example block of FIG. 1, with FIG. 2A shown in wireframe. FIG. 3 is a top view of the example block of FIG. 1. The block 100 can be used for a variety of purposes, including in various types of assemblies. For example, the block 100 can be used in retaining walls, building walls, landscape features, infrastructure projects such as overpasses and bike paths, etc.

The block 100 include regions of different material mixes. For example, the block 100 includes a region defined by a first material mix 102 (e.g. a display material 102) and a second material mix 104 (e.g., hidden material 104) different from the first material mix 102. The first material mix 102 differs from the second material mix 104 in one or more characteristics, such as one or more of material composition, color, particle size, etc. For example, each of the materials can be selected based on a variety of factors such as cost, manufacturability, availability, environmental impact, appearance, mechanical properties, chemical properties. The first material mix 102 and second material mix 104 may differ as to one or more of these factors and/or may be selected with different weighing of these factors to produce block 100 with desirable characteristics (e.g., as compared to a block made up of only one (or primarily only one) material). For example, display material may be selected due to is aesthetic properties, wear resistance, texture (for one or both of aesthetic results and for mechanical properties of the texture such as grip for foot-traffic), environmental robustness (e.g., being robust to freeze-thaw cycles or thermal expansion and contraction), anti-microbial properties, etc. The hidden material 104 may be selected due to its physical properties (e.g., load bearing, tensile strength due to aggregate, rebar, or fiber inclusions), cost, reduced environmental impact, density (either greater or lower), thermal conductivity or insulation properties (e.g., refractory cement with very good insulative properties, metal aggregate used to improve thermal conductivity), etc.

As will be explained below, the block 100 can consist entirely of only the display material 102 and the hidden material 104, or can include, partially or completely, those two materials along with other materials (e.g., one or more additional display materials and/or hidden materials of different composition, appearance, etc., as compared to display material 102 and hidden material 104) and structures. In some examples, metal fasteners can be sunk into the block 100 to aid in assembly. In some examples, computer-connected sensors can be encapsulated in the block 100 for use in monitoring the state of an assembly made with the block 100. In some example, a moisture barrier may be included in the block 100.

In an example embodiment, the block 100 is made of relatively less of the first material 102 (e.g., display material) and relatively more of the second material 104 (e.g., hidden material). In various examples, the display material 102 forms less than 50%, less than 40%, less than 30%, less than 25%, less than 20%, or less, of an overall weight of the block 100. Alternatively or additionally, the display material 102 forms less than 50%, less than 40%, less than 30%, less than 25%, less than 20%, or less, of the overall volume of the block. Alternatively or additionally, the display material 102 defines less than all sides of the block 100. For example, the display material 102 defines one or more faces of the block 100, such as a first major face of the block 100 and a side face of the block 100 adjacent to the first major face. In some embodiments, the display material 102 defines a front major face and two or more faces adjacent to the front major face. In some embodiments, the display material 102 defines all faces except a bottom major face. Alternatively or additionally, the display material 102 defines greater than 10% of the overall surface of the block, greater than 20 % of the overall surface of the block, greater than 30 % of the overall surface of the block, greater than 40 % of the overall surface of the block, or greater than 50 % of the overall surface of the block, while the display material 102 makes up less than 50 % of the overall volume of the block, less than 40 % of the overall volume of the block, less than 30 % of the overall volume of the block, less than 20 % of the overall volume of the block.

Referring still to the block 100 shown in FIGS. 1A-3, the block 100 includes six major faces, including a front facing surface 106, rear facing surface 108, top facing surface 126, and bottom facing surface 130, and side facing surfaces 130 and 132. The side facing surfaces 130 and 132 extend between front facing surface 106 and rear facing surface 108. In an example embodiment, the facing surface 106 is configured to be a front major face of block 100 that is oriented vertically in an installed assembly (e.g., an installed retaining wall). Alternatively or additionally, block 100 is configured to be installed at a corner location such that front facing surface 106 and side facing surfaces 130 and/or 132 are each at least partially or entirely visible in the installed assembly.

The facing surface 106 includes, partially or completely across facing surface 106, the display material 102. For example, the facing surface 106 is defined by display material 102 across the entirety of facing surface 106. When installed, the front surface of block 100 is thus defined by display material 102. A series of blocks 100 can be installed with respective front surfaces 106 adjacent to one another to define an assembly, such as a retaining wall, that has the appearance of the facing surfaces 106 defined by display material 102.

The side facing surface 130 includes, partially or completely across side facing surface 130, the display material 102. For example, the side facing surface 130 is defined by display material 102 across the entirety of side facing surface 130. When installed, the side surface of block 100 is thus defined by display material 102. In some embodiments, front facing surface 106 and side facing surface 130 are arranged in corner locations such that the corner of an installed assembly are defined by display material 102. The finished assembly thus has an aesthetic appearance defined by display material 102, and/or hidden material 104 is not visible are relatively less visible.

In an example embodiment, the entirety of facing surface 106 and side facing surface 130 are defined by display material 102 such that an unbroken appearance of display material 102 is provided between facing surface 106 and side facing surface 130. For example, the display material 102 visible on side facing surface and display material 102 visible on front facing surface 106 is unbroken and continuous. Such configurations can provide an appearance of a block 100 that is made entirely of display material 102 (e.g., because only surfaces defined by display material 102 are visible in the finished installation), such as when block 100 is installed in a corner location of an assembly.

The display material 102 that defines facing surface 106 has a relatively small thickness compared to an overall thickness of block 100. For example, a thickness ‘t’ of display material 102 is less than 30%, less than 20%, less than 10%, less than 5% or less of a thickness ‘T’ of the block along side surface 132. For example, the side surface 132 is defined by a relatively thin layer of display material 102 and a relatively thicker region of hidden material 104.

The block 100 includes regions defined by display material 102 and hidden material 104. The bottom facing surface 108 on a second side of block 100 includes unmixed regions defined by each of display material 102 and hidden material 104. For example, he bottom facing surface 108 includes a first area 110 defined by the display material 102, and a second area 112 defined by the display material 102, and a third area 116 defined by the hidden material 104. In various example embodiments, the first area 110 has a generally triangular appearance in which a first width of first area 110 proximate front facing surface 106 is smaller than a second width of first area 110 proximate rear facing surface 108. The second area 112 is defined by a substantially uniform thickness layer of display material 102. In an example embodiment, the first area 110 and the second area 112 are joined or continuous such that a corner of the block 100 between front facing surface 106 and side facing surface 130 is defined entirely by display material 102.

In an example embodiment, a majority of the surface area of bottom facing surface 108 is defined by hidden material 104 and a minority of the surface area of bottom facing surface 108 is defined by display material 102. For example, less than 50% of the area of bottom facing surface 108 is defined by display material 102. In various embodiments, less than 40%, less than 30%, less than 25%, less than 20%, or between about 10% and 40%, 15% and 25%, or about 20% of the bottom facing surface 108 is defined by display material 102 (e.g., and the remainder is defined by hidden material 104). Such configurations facilitate a block 100 that has a volume of relatively more hidden material 104 and relatively less display material 102, while providing a block with multiple sides defined by display material 102.

The block 100 includes a top facing surface 126 on a fourth side opposite of the bottom facing surface 108. The top facing surface 126 includes a fourth area 122 adjacent to the facing surface 106 and including, partially or completely, the display material 102. The second-hidden surface 120 can include a fifth area 124 adjacent to the top surface 126 and including, partially or completely, the display material 102. The second-hidden surface 120 can include a sixth area 125 including, partially or completely, the hidden material 104.

In some example embodiments, the display material 102 and hidden material 104 at first, second, and third areas 112, 114, 116, extend entirely through the block such that similar areas are visible on the top facing surface 126 as the bottom facing surface 128. For example, fourth, fifth, and sixth areas 122, 124, 125 correspond to and have a similar shape and appearance on the top facing surface 120 as the first, second and third areas 112, 114, 116 on the bottom facing surface 108.

In some examples, the block 100 includes at least one lug 118. The lug 118 protrudes from the profile of the surrounding block 100, for example for mechanical purposes. The lug 118 may provide a mating surface that interacts with other surfaces or edges of an adjacent block to facilitate alignment and assembly of respective blocks 100 during installation. In some embodiments, lug 118 may interact with lugs or lug-shaped-depressions in other blocks or other structures to secure the block 100, and/or the lug 118 can be used to “lock” the block 100 into an assembly such as a wall or structure. In various examples, the lug 118 includes hidden material 104. For example, if protruding from the third area (made of the hidden material 104), the lug 118 is also made of the hidden material 104. In an example embodiment, the lug 118 is made entirely of hidden material 104. In various examples, the lug 118 can include the display material 102. For example, if protruding from the first area 110 or the top surface 126 (made of the hidden material 104), the lug 118 may (also) be made of the hidden material 104. In various examples, the lug 118 can include both the display material 102 and the hidden material 104. For example, if spanning across the first area 110 (made of the display material 102) and second area 112 (made of the hidden material 104), the lug 118 may be made of both the display material 102 and the hidden material 104.

The block 100 can be manufactured according to a variety of dimensions and proportions. In an example embodiment, the block 100 has a front facing surface having dimensions of about 40 in. by 8 in., and the bock 100 has a depth of about 12 in. In various example embodiments, the front facing surface has a length between about 6 in and 72 in., 12 in. and 60 inch., or about 40 in., a width of about 4 in. to 24 in., 6 in. to 16 in., or about 8 in., and the block 100 has a depth of between about 4 in. and 36 in., 6 in. and 16 in., or about 8 in. Such dimensions provide blocks suitable for assembly into retaining walls or other structures that are readily manipulated and structurally effective.

Various materials and techniques may be used to modulate the aesthetics of the display material 102. In various examples, the display material 102 includes a material mix that makes up the hidden material 104 with the addition of a colorant. Such an arrangement can facilitate similar structural performance and compatibility between the different material mixes, while provide a desired aesthetic appearance for the display material 102.

In various example, the colorant includes one or more agents that are safe and effective for coloring the concrete or stone mixture. Some such example colorants include a dry pigment powder. For example, metal oxides (e.g., titanium oxide for a white appearance, various iron oxides for red or black appearances, copper oxide for a verdigris appearance). For example, organic or synthetic pigments can be used (e.g. quinacridone for a violet or red appearance, PY62 for a yellow appearance). As will be appreciated, single pigments can be used, or pigment blends can be used. Some such example colorants include, but are not limited to a liquid suspension of the dry pigment powder. For example, the various dry pigment powders may be suspended in an aqueous solution (e.g., water, ethanol), optionally with a binder (e.g., acrylic medium, Gum Arabic) and/or other additions. Some such example colorants include, but are not limited to a liquid dye. For example, various solvents (e.g., water, alkaline liquor) can dissolve one or more chromophore compounds to impart a desired color (e.g., indigo for a blue appearance, acid red 88 for a red appearance). Some such example colorants include, but are not limited to mineral aggregate or another type of aggregate. For example, rocks, sand, glass, ceramics, or other minerals (or non-minerals) may be selected based on their color, texture, or other surface feature and used. In some cases, a single aggregate may be used. In some cases, a mix of different aggregates can be used. The density of the aggregate may be greater or lesser, depending on the desired finish of the display material (e.g., whether significant amounts of cement be visible around the aggregate, or whether the display material have an appearance defined mostly by the mineral aggregate). In some examples, the hidden material 104 is a first concrete, and the display material 102 is a curing material different than the first concrete. For example, the display material 102 may be only the cement from the hidden material 104 so that a smoother finish is provided, while the mechanical advantages of the aggregate are still maintained by other portions of the block 100.

FIG. 4 is a side view of an example block 400. As can be seen, the block 400 differs from the block 100 by having both side portions with the display material 102. This may be useful, for example, in cases in which an assembly calls for only a single layer of blocks that will be exposed on both the front and the back of the assembly (e.g., a wall that is a single block thick), or for blocks that will be positioned with each side exposed.

The block 400 includes a second-facing surface 402 on a third side opposite of the facing surface 404. The second-facing surface 402 can include, partially or completely, the display material 102. The block 400 can include a hidden surface 406 that can include, partially or completely, a seventh area 408 consisting of the display material 102.

FIG. 5 is a perspective view of an example block mold 500. FIG. 6 is a schematic view of an example manufacturing system 600. For example, the manufacturing system 600 can be used to fill one or more block mold 500 to manufacture one or more blocks 100 and/or blocks 400.

The manufacturing system 600 includes a controller 602, control station 604 with a graphical user interface (GUI 606) for user input and output, a collection of molds 500, a display material source 608, a hidden material source 610, a compactor 612, and a pallet handler 614.

The controller 602 includes a processor and memory, and can be configured to control other elements of the manufacturing system 600. The GUI 606 can be used to allow users to interact with the controller 602, for example, to start, stop, or modify manufacturing processes performed by the controller 602.

The display material source 608 includes one or more hoppers, loading trays, nozzles, motors, tracks, and/or other elements to deposit display material 102 into the molds 500. The hidden material source 610 includes one or more hoppers, loading trays, nozzles, motors, tracks, and/or other elements to deposit hidden material 104 into the molds 500. Both the display material source 608 and hidden material source 610 can include automation elements that allow the controller 602 to issue commands to deposit specified amounts (e.g., volumes, weights) of display material 102 and hidden material 104, respectively, into specified locations in the molds 500. The controller 602 can cause the manufacturing system 600 to fill the molds 500 with display material 102 and hidden material 104 in patterns configured to create the block 100 and/or block 400.

The manufacturing system 600 is configured to move the molds 500 relative to the display material source 608 and the hidden material source 610, and/or vice versa. In various examples, the molds 500 are held by a mold manipulator that move the molds 500 in space in response to instructions from the controller 602, while the display material source 608 and hidden material source 610 can be fixed in space. In various examples, the display material source 608 and hidden material source 610 can include elements (e.g., linear actuators, rollers and rails, motors) to move in space in response to instructions from the controller 602, while the molds 500 can be fixed in space. Alternatively or additionally, both the molds 500 and material sources 608 and 610 move in space and are positioned relative to one another to distribute material sequentially into the molds 500 according to a predetermined dispensation sequence.

The compactor 612 includes elements to selectively apply compaction to the contents of the molds 500. For example, the controller 602 can instruct the compactor 612 to selectively compact the molds 500 at various times, with various parameters (e.g., a vibration frequency, a hydraulic pressure) in coordination with other operations of the manufacturing system 600. In various example, the compaction applied by the compactor 612 can include one or more of i) vibrating (e.g., an offset cam rotating about a shaft attached to the molds 500), ii) tamping (e.g., a plate pressed with a hydraulic system into the molds 500), and iii) impacting (e.g., a hammer impacting a striking surface of the molds 500, possibly repeatedly).

The pallet handler 614 can operate to place blocks from the molds 500 onto pallets or other appropriate shipping containers. For example, the pallet handler 614 responds to instructions from the controller 602 to move an empty pallet into position to receive demolded blocks, and place the demolded blocks onto the pallet in a pre-defined pattern until the pallet is full. Then the pallet handler 614 can move the loaded pallet away to make room for a fresh, empty pallet.

To create a block, the manufacturing system 600 operates at a first time with the controller 602 instructing the display material source 608 to deposit, a first portion of display material 102 into a first-target location. For example, this first-location may correspond to the first area 110 of block 100.

In various example embodiments, the display material 102 is deposited into the first-target location be depositing a predetermined amount of material at predetermined locations of the mold. For example, the amount of display material 102 deposited into the first-target location is sufficient to extend to a predetermined height within the mold (e.g., at a location near a side wall of the mold as shown in FIG. 8B). In an example embodiment, the display material 102 is deposited to have a height greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or 100% or greater of a height of the mold cavity that defines the shape of the resulting block. Such heights of display material 102 facilitates sufficient material to define an entire facing surface (e.g., side facing surface 130 in FIG. 1A) with display material 102 such that hidden material 104 is not visible on the side facing surface.

In an example embodiment, the display material 102 is deposited to reach a predetermined height, as described above, without covering the entirety of the bottom of the mold cavity. For example, the display material 102 is deposited to form a pile in one region of the mold cavity (e.g., at a location near a side wall of the mold) while a remainder of a bottom of the mold cavity remains uncovered. In various example embodiments, the display material 102 covers less than 75%, less than 70%, less than 60%, less than 50%, less than 40%, less than 30%, less than 20%, less than 10%, of an entire length of a bottom of the mold cavity, or between about 20 % and 40% of the bottom of the mold cavity.

In an example embodiment, the display material 102 can be piled to facilitate sufficient coverage to define an entire side surface of a resulting block without the use of additional stencils or dividers. The display material 102 is deposited on top of itself to form a pile, facilitating efficient manufacture of a block having a desired aesthetic appearance.

Then, at a second time after the first time, the manufacturing system 600 can operate with the controller 602 instructing the hidden material source 610 to deposit a second portion of hidden material 104 into a second-target location. For example, the second-location may correspond to the second area 112 of block 100.

Then, at a third time after the second time, the manufacturing system 600 can operate with the controller 602 instructing the compactor 612 to apply compaction to the second portion of molds 500 to urge, into a lug-portion of the mold, the hidden material 104. In some examples, the compaction applied in the third time is the only compaction applied in the manufacturing process. In some examples, compaction can be applied at other time (such as in the fifth time described below).

Then, at a fourth time after the third time, the manufacturing system 600 can operate with the controller 602 instructing the display material source 608 to deposit, a third portion of the hidden material 104 on top of both the first portion and the second portion.

Then, at a fifth time after the fourth time, the manufacturing system 600 can operate with the controller 602 instructing the compactor 612 to apply compaction to the third portion to urge, into a lug-portion of the mold, the hidden material 104. For example, the compaction can be applied directly to the third portion only, such that the compaction is applied directly only to the display material. In such an example, the force of the compaction can be transferred through the display material, into and through the hidden material, and into display and/or hidden material that fills the lug portions of the mold. In some examples, the compaction applied in the fifth time is the only compaction applied in the manufacturing process. In some examples, compaction can be applied at other times (such as in the third time described above). Such compaction can facilitate efficient manufacturing and enhance throughput by performing compaction (e.g., sufficient to compact the material that defines lugs 118) via a colored material mix that defines an aesthetic surface of the finished block. The compaction can thus take place when all material, including a colored display material, is in the mold.

Then, at a sixth time after the fifth time, the manufacturing system 600 can operate with the controller 602 instructing molds 500 to store their blocks for a predetermined amount of time. In various examples, the controller 602 can instruct the molds 500 to maintain various conditions such as temperature, humidity, movement etc.

Then, at a seventh time after the fifth time, the manufacturing system 600 can operate with the controller 602 instructing the molds 500 and/or the pallet handler 614 to demold one or more blocks of the display material and the hidden material.

In various example, the molds 500 include cavities to manufacture more than one block. For example, the molds 500 are shaped with four cavities. In such instances, the manufacturing system 600 operations can include depositing, into a second block mold, the display material and the hidden material; depositing, into a third block mold, the display material and the hidden material; depositing, into a fourth block mold, the display material and the hidden material.

FIGS. 7A and 7B are a top views of example blocks having alternating lug locations. As shown in FIG. 7A, on a pallet 710, a block 702 and a block 704 are shaped and arranged to be packed together, and a block 706 and a block 708 are shaped to be packed together. For example, the manufacturing system 600 can manufacture the block 702, block 704, block 706, and block 708 and load them onto the pallet 710 with the pallet handler 614. In various example embodiments, blocks 702 and 704 have one or more features described above with reference to block 100.

To make the block 702 and block 704, a corresponding block mold and block mold can include lug-portions at offset locations. To make the block 706 and block 708, a corresponding block mold and block mold can include lug-portions at offset locations. For example, blocks 702 and 706 have a first lug configuration, and blocks 704 and 708 have a second lug configuration. The first and second lug configurations are different and complementary, such that the blocks can be positioned in close proximity without interference between lugs of respective blocks.

To load the block 702, block 704, block 706, and block 708 onto the pallet 710, the pallet handler 614 can load block 702 and block 704 arranged with interlacing lug-portions, and block 706 and block 708 arranged with interlacing lug-portions.

As shown in FIG. 7B, on a pallet 710, a block 712 and a block 714 are shaped and arranged to be packed together, and a block 716 and a block 718 are shaped to be packed together. For example, the manufacturing system 600 can manufacture the block 712, block 714, block 716, and block 718 and load them onto the pallet 710 with the pallet handler 614.

To make the block 712 and block 714, a corresponding block mold and block mold can include lug-portions at offset locations. To make the block 716 and block 718, a corresponding block mold and block mold can include lug-portions at offset locations.

To load the block 702, block 704, block 706, and block 708 onto the pallet 710, the pallet handler 614 can load block 702 and block 704 arranged with interlacing lug-portions, and block 706 and block 708 arranged with interlacing lug-portions.

FIGS. 8A-8F show operations of filling masonry block molds. FIGS. 8A-8D show a filling of a mold 500 first with display material 102, then with hidden material 104, then with display material 102. In FIG. 8A, an empty mold 500 is shown, prepared for filling with display material 102 and hidden material 104. Then, in FIG. 8B, the display material 102 is added in a first-target location in the mold 500. Then, in FIG. 8C, the hidden material 104 is added in a second-target location in the mold 500. Then, in FIG. 8D, the display material 102 is added in a third-target location on top of the previously loaded display material 102 and hidden material 104. In various example embodiments, the block

FIGS. 8E-8H show a different example in which the hidden material 104 is first loaded into the mold 500, then the display material 102 is loaded into the mold 500. In FIG. 8E an empty mold 500 is shown, prepared for filling with display material 102 and hidden material 104. Then, in FIG. 8F, the hidden material 104 is added in the second-target location in the mold 500. Then, in FIG. 8G, the display material 102 is added in the first-target location in the mold 500. Then, in FIG. 8H, the display material 102 is added in a third-target location on top of the previously loaded display material 102 and hidden material 104.

FIG. 9 shows an example of a computing device 900 and an example of a mobile computing device that can be used to implement the techniques described here. The computing device 900 is intended to represent various forms of digital computers, such as laptops, desktops, workstations, personal digital assistants, servers, blade servers, mainframes, and other appropriate computers. The mobile computing device is intended to represent various forms of mobile devices, such as personal digital assistants, cellular telephones, smart-phones, and other similar computing devices. The components shown here, their connections and relationships, and their functions, are meant to be exemplary only, and are not meant to limit implementations of the inventions described and/or claimed in this document.

The computing device 900 includes a processor 902, a memory 904, a storage device 906, a high-speed interface 908 connecting to the memory 904 and multiple high-speed expansion ports 910, and a low-speed interface 912 connecting to a low-speed expansion port 914 and the storage device 906. Each of the processor 902, the memory 904, the storage device 906, the high-speed interface 908, the high-speed expansion ports 910, and the low-speed interface 912, are interconnected using various busses, and can be mounted on a common motherboard or in other manners as appropriate. The processor 902 can process instructions for execution within the computing device 900, including instructions stored in the memory 904 or on the storage device 906 to display graphical information for a GUI on an external input/output device, such as a display 916 coupled to the high-speed interface 908. In other implementations, multiple processors and/or multiple buses can be used, as appropriate, along with multiple memories and types of memory. Also, multiple computing devices can be connected, with each device providing portions of the necessary operations (e.g., as a server bank, a group of blade servers, or a multi-processor system).

The memory 904 stores information within the computing device 900. In some implementations, the memory 904 is a volatile memory unit or units. In some implementations, the memory 904 is a non-volatile memory unit or units. The memory 904 can also be another form of computer-readable medium, such as a magnetic or optical disk.

The storage device 906 is capable of providing mass storage for the computing device 900. In some implementations, the storage device 906 can be or contain a computer-readable medium, such as a floppy disk device, a hard disk device, an optical disk device, or a tape device, a flash memory or other similar solid state memory device, or an array of devices, including devices in a storage area network or other configurations. A computer program product can be tangibly embodied in an information carrier. The computer program product can also contain instructions that, when executed, perform one or more methods, such as those described above. The computer program product can also be tangibly embodied in a computer-or machine-readable medium, such as the memory 904, the storage device 906, or memory on the processor 902.

The high-speed interface 908 manages bandwidth-intensive operations for the computing device 900, while the low-speed interface 912 manages lower bandwidth-intensive operations. Such allocation of functions is exemplary only. In some implementations, the high-speed interface 908 is coupled to the memory 904, the display 916 (e.g., through a graphics processor or accelerator), and to the high-speed expansion ports 910, which can accept various expansion cards (not shown). In the implementation, the low-speed interface 912 is coupled to the storage device 906 and the low-speed expansion port 914. The low-speed expansion port 914, which can include various communication ports (e.g., USB, Bluetooth, Ethernet, wireless Ethernet) can be coupled to one or more input/output devices, such as a keyboard, a pointing device, a scanner, or a networking device such as a switch or router, e.g., through a network adapter.

The computing device 900 can be implemented in a number of different forms, as shown in the figure. For example, it can be implemented as a standard server 920, or multiple times in a group of such servers. In addition, it can be implemented in a personal computer such as a laptop computer 922. It can also be implemented as part of a rack server system 924. Alternatively, components from the computing device 900 can be combined with other components in a mobile device (not shown), such as a mobile computing device 950. Each of such devices can contain one or more of the computing device 900 and the mobile computing device 950, and an entire system can be made up of multiple computing devices communicating with each other.

The mobile computing device 950 includes a processor 952, a memory 964, an input/output device such as a display 954, a communication interface 966, and a transceiver 968, among other components. The mobile computing device 950 can also be provided with a storage device, such as a micro-drive or other device, to provide additional storage. Each of the processor 952, the memory 964, the display 954, the communication interface 966, and the transceiver 968, are interconnected using various buses, and several of the components can be mounted on a common motherboard or in other manners as appropriate.

The processor 952 can execute instructions within the mobile computing device 950, including instructions stored in the memory 964. The processor 952 can be implemented as a chipset of chips that include separate and multiple analog and digital processors. The processor 952 can provide, for example, for coordination of the other components of the mobile computing device 950, such as control of user interfaces, applications run by the mobile computing device 950, and wireless communication by the mobile computing device 950.

The processor 952 can communicate with a user through a control interface 958 and a display interface 956 coupled to the display 954. The display 954 can be, for example, a TFT (Thin-Film-Transistor Liquid Crystal Display) display or an OLED (Organic Light Emitting Diode) display, or other appropriate display technology. The display interface 956 can comprise appropriate circuitry for driving the display 954 to present graphical and other information to a user. The control interface 958 can receive commands from a user and convert them for submission to the processor 952. In addition, an external interface 962 can provide communication with the processor 952, so as to enable near area communication of the mobile computing device 950 with other devices. The external interface 962 can provide, for example, for wired communication in some implementations, or for wireless communication in other implementations, and multiple interfaces can also be used.

The memory 964 stores information within the mobile computing device 950. The memory 964 can be implemented as one or more of a computer-readable medium or media, a volatile memory unit or units, or a non-volatile memory unit or units. An expansion memory 974 can also be provided and connected to the mobile computing device 950 through an expansion interface 972, which can include, for example, a SIMM (Single In Line Memory Module) card interface. The expansion memory 974 can provide extra storage space for the mobile computing device 950, or can also store applications or other information for the mobile computing device 950. Specifically, the expansion memory 974 can include instructions to carry out or supplement the processes described above, and can include secure information also. Thus, for example, the expansion memory 974 can be provide as a security module for the mobile computing device 950, and can be programmed with instructions that permit secure use of the mobile computing device 950. In addition, secure applications can be provided via the SIMM cards, along with additional information, such as placing identifying information on the SIMM card in a non-hackable manner.

The memory can include, for example, flash memory and/or NVRAM memory (non-volatile random access memory), as discussed below. In some implementations, a computer program product is tangibly embodied in an information carrier. The computer program product contains instructions that, when executed, perform one or more methods, such as those described above. The computer program product can be a computer-or machine-readable medium, such as the memory 964, the expansion memory 974, or memory on the processor 952. In some implementations, the computer program product can be received in a propagated signal, for example, over the transceiver 968 or the external interface 962.

The mobile computing device 950 can communicate wirelessly through the communication interface 966, which can include digital signal processing circuitry where necessary. The communication interface 966 can provide for communications under various modes or protocols, such as GSM voice calls (Global System for Mobile communications), SMS (Short Message Service), EMS (Enhanced Messaging Service), or MMS messaging (Multimedia Messaging Service), CDMA (code division multiple access), TDMA (time division multiple access), PDC (Personal Digital Cellular), WCDMA (Wideband Code Division Multiple Access), CDMA2000, or GPRS (General Packet Radio Service), among others. Such communication can occur, for example, through the transceiver 968 using a radio-frequency. In addition, short-range communication can occur, such as using a Bluetooth, WiFi, or other such transceiver (not shown). In addition, a GPS (Global Positioning System) receiver module 970 can provide additional navigation-and location-related wireless data to the mobile computing device 950, which can be used as appropriate by applications running on the mobile computing device 950.

The mobile computing device 950 can also communicate audibly using an audio codec 960, which can receive spoken information from a user and convert it to usable digital information. The audio codec 960 can likewise generate audible sound for a user, such as through a speaker, e.g., in a handset of the mobile computing device 950. Such sound can include sound from voice telephone calls, can include recorded sound (e.g., voice messages, music files, etc.) and can also include sound generated by applications operating on the mobile computing device 950.

The mobile computing device 950 can be implemented in a number of different forms, as shown in the figure. For example, it can be implemented as a cellular telephone 980. It can also be implemented as part of a smart-phone 982, personal digital assistant, or other similar mobile device.

Various implementations of the systems and techniques described here can be realized in digital electronic circuitry, integrated circuitry, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and/or combinations thereof. These various implementations can include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which can be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device.

These computer programs (also known as programs, software, software applications or code) include machine instructions for a programmable processor, and can be implemented in a high-level procedural and/or object-oriented programming language, and/or in assembly/machine language. As used herein, the terms machine-readable medium and computer-readable medium refer to any computer program product, apparatus and/or device (e.g., magnetic discs, optical disks, memory, Programmable Logic Devices (PLDs)) used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term machine-readable signal refers to any signal used to provide machine instructions and/or data to a programmable processor.

To provide for interaction with a user, the systems and techniques described here can be implemented on a computer having a display device (e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor) for displaying information to the user and a keyboard and a pointing device (e.g., a mouse or a trackball) by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback); and input from the user can be received in any form, including acoustic, speech, or tactile input.

The systems and techniques described here can be implemented in a computing system that includes a back end component (e.g., as a data server), or that includes a middleware component (e.g., an application server), or that includes a front end component (e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the systems and techniques described here), or any combination of such back end, middleware, or front end components. The components of the system can be interconnected by any form or medium of digital data communication (e.g., a communication network). Examples of communication networks include a local area network (LAN), a wide area network (WAN), and the Internet.

The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.