CA1287734C

CA1287734C - Biaxial concrete masonry casting method and apparatus

Info

Publication number: CA1287734C
Application number: CA000500993A
Authority: CA
Inventors: Jorge Pardo
Original assignee: National Concrete Masonry Association
Current assignee: National Concrete Masonry Association
Priority date: 1985-02-04
Filing date: 1986-02-03
Publication date: 1991-08-20
Anticipated expiration: 2008-08-20
Also published as: AU5299086A; IT8647583A0; IT1190455B; GB2170442A; DE3602070A1; GB8602681D0; GB2170442B; AU593535B2; FR2576829A1; FR2576829B1; JPS61246011A

Abstract

ABSTRACT
A concrete mold core assembly and method for making a concrete masonry block is disclosed. The assembly comprises a mold box including side walls for forming at least part of a mold cavity. At least one mold core has substantially vertically disposed walls establishing with the side walls a mold cavity open at the top and bottom thereof. The axis extends vertically between the top and bottom ends as a casting axis. The mold core contains laterally extending plungers movable into the mold cavity along an axis transverse to the casting axis. A material's feed tray is movable into an overhead position above the mold box to feed liquid concrete into the mold cavity. A pallet is movable into position adjacent the bottom end of the mold cavity to establish a mold cavity bottom retaining the concrete and the mold cavity to form the block. A compression stripper shoe movable in the direction of the casting axis strips the cast block from the mold cavity in coordination with the pallet being moved to a spaced location away from the mold cavity bottom. Control means is provided for selectively extending the laterally projecting means into the mold cavity and the control is operable to retract the laterally projecting means from the cavity following introduction of liquid concrete into the mold cavity. Retraction of the plungers from the mold cavity occurs prior to removal of the pallet from the mold cavity bottom.
The control means senses full retraction of the laterally projecting plungers from the mold cavity to thereby enable prevention of removal of the pallet in response to failure of the plungers to fully retract.

Description

L2~7 ~
;

BIAXIAL CONCRETE MASONRY
CASTING MET~IOD AND APPARATUS

-The present invention relates to novel methods and apparatus for biaxial casting of concrete masonry products such as concrete masonry blocks so as to produce openings and shape indenta-tions along the axis perpendicular to the axis of casting.
The prevailing system for manufacture of concrete masonry blocks and like units ("CM blocks", "CM units" or "CM products") is characterized by a methodology in which a fluid or semifluid eoncrete masonry ("CM") composition is compression cast within a mold and the CM product stripped at the opposite end from which it was fed and along the same axis. The process is similar to that of extrusion except that in the concrete masonry industry the CM product is produced in discreet segments or units rather ~than as a continuous casting such as is used to form products of relatively long length. One of the limiting parameters of such existing CM block manufacturing process is established by the fact that since the accretion of the molding materials oeeurs lineally along -the axis of the mold aperture the resultant CM
produet shapes which can be made may be varied only as a funetion of the mold aperture eross section. That is, the shape of the CM
blocks or other CM products made with prior existing methods and equipment is basically limited to variation in the same axis as that of the flow of the material in the casting process. This limitation necessitates that CM product shape modification along the axis perpendicular to the flow of the material during casting becomes an expensive secondary manufacturing step which in most cases cannot be economically justified.
I'here have been some systems developed for making CM
products provided with shape indentations along an axis perpendicular to the casting direction axis. One example is a ~"~lorizontal Core Adapter" system made and sold by Besser Company IOE ~lpena, Michigan, whereby i-t is possible to make concrete ;masonry blocks having top and/or bottom surfaces indented to provide interlocking blocks, reinforcement blocks or decorative blocks. However, such systems have short-comings in that the equipment is relatively expensive, the rate of CM block production is relatively slow, and the molds tend to wear out very quickly because the CM materials are very abrasive. It is noted, however, that such prior systems here mentioned do not involve a biaxial concrete masonry casting method and apparatus such as disclosed herein and claimed as my invention.
The present invention provides a new technological approach including novel method and apparatus for manufacturing CM blocks or other CM products based on variation of the mold aperture during casting timed in such a way that it results in CM product jshape varia-tions along an axis normal to the axis of CM material flow. This eliminates the necessity of secondary manufacturing operations to produce such openings or other shape variations along the axis of the CM product perpendicular to the axis of ! casting.
The biaxial concrete masonry casting method and apparatus of this invention is achieved by a novel relatively inexpensive ,modification of a conventional CM mold core system to provide a biaxial CM mold core system which may be readily installed or retrofitted in commercially available CM casting machines for making CM blocks and like products. Thus conventional CM
casting machines can be converted at low cost for fast and economical biaxial casting of CM blocks and other CM products so as to produce such products having openings and shape inden-tations alon~ an axis of the product perpendicular to the axis of casting~ It is an important feature of the present invention that the novel biaxial CM mold core apparatus for this new system is compact for use in existing molds of commercially ~ 73~ 70454-1 available CM casting machines. Specifically, such new apparatus according to the present invention incorporates reciprocal actuating plungers which cause biaxial shape modiEi.cation oE the CM blocks or like CM products during casting but are contained within the confines of mold cores such as normally used for making C~ products having conventional cavities extending in the direction of the axis of casting.
It is an object of the present invention to provide CM blocks or like products having cavities extending not only along the axis of casting but also having apertures in one or more of the center and end web portions o:E the CM blocks and/or in the face shells thereof, such apertures extending along an axis normal to the direction of material flow during casting, with such apertures being made in a single casting operation without any secondary operations.
To achieve the foregoing objects, there is disclosed a biaxial casting apparatus for making a concrete masonry or CM
block including at least one face shell, the apparatus adapted to be disposed in the mold of a CM casting machine with the mold including a mold box comprising side wall means and a movable bottom. The biaxial casting apparatus comprises at least one mold core means forming a mold cavity with the side wall means.
The mold core means includes means for laterally projecting out-wardly from the side wall means o E the mold core means into the mold cavity along an axis transverse to the side wall means of the mold core means during selected phases of using the appara-tus and casting a concrete masonry block. Control means is provided for selectively extending and retracting the laterally projecting means. The control means includes means for sensing full retraction of the laterally projecting means from the mold ,. '.:, . . ,.,~:

~ 3~ 70454-1 cavity to thereby enable prevention of removal of the movable bottom in response to failure of the laterally projecting means to fully retract as sensed by the sensing means.
The control means may further comprise air supply means for pneumatically extending and retracting the laterally projecting means. The laterally projecting means preferably includes at least one plunger extendable into the mold cavity through an opening in the vertically disposed side wall means.
In accordance with a preferred feature of the inven-tion, at least one sweeper gasket is disposed between an outerperiphery of the plunger and an inner periphery of a manifold member housing the plunger which inner periphery opposes the outer periphery to wipe concrete material from an exterior surface of the plunger during retraction. The manifold member may further include a first set of passageways connected to air supply means for pneumatically operating the plunger to supply air into a portion of the hollow area of the plunger defined by one side of a piston to retract the plunger from its extended mode. A second set of air supply passages supply air to the other side of the piston to extend the plunger in its extension mode.
The invention may further include means for venting air from within the manifold through the plunger to break the negative pressure and vacuum effect around the periphery of the plunger within the mold cavity as the plunger starts to retract from its extended mode.
The control means may further include air pressure supplied nipple means positioned to be blocked off by an exterior periphery of a plunger in its fully retracted mode. The sensing means communicates with the nipple means to detect a minimum . ~.

~ 70~54-1 back pressure applied thereto by blockage of the nipple means by the plunger to determine whether the plunger has Eailed to retract iE the sensor means senses a back pressure be~ow the minimum back pressure.
The mold aperture may be varied dur_ng castlng timecl in such a way that it will result in apertures in one or more of the cen-ter and two end webs of the CM blocks, and in the face shells thereof, such aperture being formed along an axis normal to flow of the CM materials during casting ~called the "axis of casting~
The disclosed methocl and apparatus can make such CM
blocks having openings in the webs thereof, and in their face shells, along an axis or axes perpendicular to the axis of cast-ing at a fast rate of production comparable and competitive with typieal cornmercial production rates for making eonventional CM
bloeks, for example, a bloek about every six seconds.
The invention can provide a biaxially cast CM "T-block" which has openings in one end web and the center web thereof extending along a second axis perpendicular to a first axis of casting of the CM block plus two substantially aligned openings in opposite face shells of the CM block extending along a third axis perpendicular to the axis of casting and also perpendicular to said second axis of said web openings. In such a biaxially east CM T-bloek plumbing and/or eleetrical con-duits or the like and/or air can pass through all or some of said openings in the T-block. Such a biaxially cast CM T-block can be used for interconnecting CM bloek walls made of biaxially east CM blocks having openings in each of the three webs of such CM block. The openings in said webs and face shells are simul-taneously made during casting of the CM block without secondary operations (sometimes called "triaxial CM casting", as well as "biaxial CM casting").

~, ~7~3~ 70454-1 A biaxially cast CM "L-block" has openings in one end web and the center web thereoE extending along a second axis perpendicular to a first axis of casting, plus one opening in one of the face shells of the L-block adjacent another end web of said block (which does not have an openiny therein) said opening in said face shell extending along a third axis perpen-dicular to the axis of casting and also perpendicular to said second axis. In such a biaxially cast CM L-block plumbing and/or electrical conduits or the like and/or air can pass through said openings in the L-block. Such biaxially cast CM
L-blocks are used for making the corners between two walls made up of biaxially cast CM blocks which have openings in each of the webs thereof extending in a direction along said second axis perpendicular to the axis of casting. The openings in said webs and said face shells are simu]taneously made during casting of the CM block without secondary operations (sometimes called "triaxial CM casting", as well as "biaxial CM casting").
Biaxially cast CM blocks having openings in the cen-ter and two end webs thereof, and in the face shells thereof, are producible with commercially available fast-rate CM casting machines so that such biaxially cast CM blocks may be used to make concrete masonry block walls and like structures with the openings in the CM block webs providing horizontally extending conduits within such CM block walls. Such horizontally extend-ing conduits in the CM blocks may be used for accommodating wiring or plumbing pipe or the like extending horizontally with CM block walls made with biaxially cast CM blocks. Such horizontally extending openings and conduits also enable dis-tribution of air through such CM block walls.
The disclosed biaxially cast CM blocks with openings - 5a -~ 7~ 70~5~1 in the center and side webs, and sometimes also in the face shells, use less concrete masonry material, ye-t malntain ade~u-a-te strength in the field. Such biaxially cast CM blocks and like products are lighter and better for shipment and assembly;
and can be more easily hand-held and manipulated by workmen when constructing walls or the like in the field; and have a number of other advantages now made realizable by use of the novel methods and apparatus for biaxial casting of such CM
blocks at a fast rate with existing commercially available CM
block casting machinery.
The present invention provides novel method and apparatus for biaxial casting of CM blocks and other CM
products so as to provide openings and shape - 5b -~3~ 39~

indentations along an axis perpendicular to the axis of casting and a~hieve various other objects and advantages which are stated below in the description of the present inventions.
The above discussed and other objects and advantages of the present inventions will become apparent from the following specification, appended claims and the accompanying drawings in which:
Figure 1 is a perspective view of a conventional twin-cavity CM block such as made with commercially available CM block casting machines in which a semifluid concrete masonry mix is compression cast within a mold and stripped at the opposite end from which it was fed along the axis of casting.
. Figure 2 is an isometrlc view of a biaxially cast CM
block which is generally similar to the conventional CM block . shown in Figure 1 but has apertures in the center and two end webs of the bloc]c made during casting of the block using my novel :method and apparatus for biaxial casting according to the present invention.
Figure 3 is a top plan view of the biaxially cast CM
block shown in Figure 2.
Figure 4 is an end elevation view of the biaxial.ly cast CM block shown in Figures 2 and 3.
Figure 5 is a longi-tudinal cross-sectional view of the biaxially cast CM block taken along line 5-5 in Figure 3.
Figure 5A is an isometric view of a modified biaxially cast CM block which is like the biaxially cast CM block of Figures 2-5, but is modified so that its end webs are in alignment with the ends of its face shells rather than being spaced therefrom as in the block of Figures 2-5.
Figure 6 is a schematic or diagrammatic illustration of components of a biaxial CM casting apparatus in one phase of a biaxial CM casting process for making biaxial CM blocks according to the present invention. Figure 6 shows a biaxial CM mold core 773~

system according to the present invention installed in the mold box of a conventional CM casting machine; and this figure shows `the mold being fed a conventional bottom pallet, with the compression/stripper shoe on its way up to provide access for the feed tray to the mold.
Figure 7 is a schematic of the biaxial CM casting apparatus components shown in Figure 6 but in another phase of the biaxial CM casting process wherein the bottom pallet is in place and the axial plungers are extended from the biaxial CM
mold cores (whereas in Figure 6 su¢h axial plungers are retracted within such cores).
Figure 8 is a schematic of the biaxial CM casting apparatus components shown in Figure 7 but in another phase of the process wherein semifluid concrete masonry mlx is being fed into the mold cavity while said axial plungers are extended from the biaxial CM mold cores.
Figure 9 is a schematic of the apparatus of Figure 8, but shows another phase of the process wherein the feed tray has withdrawn and the stripper shoe has come down to compress the CM
'mix in the mold as vibration proceeds while said axial plungers are extended from the biaxial CM mold cores.
Figure 10 is similar to that of Figure 9 but shows another phase wherein the axial plungers are being retracted to inside the biaxial mold cores after completion of the CM block compression cycle.
Figure 11 is similar to Figure 10 but shows another phase wherein the axial plungers are fully retracted within the hollow mold cores and the compressed CM material formed into a CM
block is being stripped from the mold cavity through simultaneously downward motion of the compression/stripper shoe and the bottom pallet. `

- . ~ f .

3~

Figure 12 is a schematic drawing showing various components of the biaxial CM casting apparatus shown in Figures 6 through 11, but Figure 1~ illustra-tes ano-ther phase of the process wherein the compression/stripper shoe returns upward past the axial plungers which are retracted within the biaxial CM
mold cores, while the newly cast CM block is being ejected on its individual pallet onto a conveyor - whereby the steps of Figures 6 through 11 can be repeated when the compression/stripper shoe moves upwardly out of and above the mold box.
Figure 13 is a partly cross-sectional view and par-tly side-elevational view of a biaxial CM mold core system plus mounting means and air conduit means for installing and operating the biaxial CM mold core system in a commercially available CM
block casting machine. In the mold core on the right side of Figure 13, the axial plungers are shown fully retracted within the mold core as they would be in phases of operation illustrated in Figures 6, 11 and 12 hereof. In contrast, for convenient disclosure, the mold core on the left side of Figure 13 shows the axial plungers fully extended from the mold core as they would be ;in phases of operation shown in Figures 7, 8 and 9 hereof.
Figure 14 is a perspective view (looking from the top) of the biaxial CM mold core system plus related mounting means and air conduit means shown in Figure 13.
Figure 15 is a perspective view showing part of a conventional CM block cas-ting machine and the biaxial CM mold core system and related components shown in Figures 13 and 14 installed in the CM block casting machine with the -two mold cores of said system disposed in the mold box of the casting machine.

Figure 16 is a cross-sectional view of the biaxial plungers sub-assembly shown in Figure 13, taken along line 16-16 of the mold core shown at the right side of Figure 13.

37~3~L

Figure 17 is a bottom plan view of the mold core assemblies shown in Figures 13 and 14, looking upwardly along line 17-17 in Figure 13.
Figure 18 is a schematic or diagrammatic illustration of a modified biaxial CM casting apparatus for use in a CM
manufacturing process for making biaxial CM blocks according to the present inven-tion. The modified apparatus of Figure 18 corresponds to part of the embodiment shown in Figures 6-12 but shows a biaxial CM mold core system including only three axial plungers, one in the mold core at the left of Figure 18 and two in the mold core at the right of Figure 18 (said axial plungers being shown in fully retracted position in -this figure).
Figure 19 is a schematic illustration of the modified biaxial CM apparatus shown in Figure 18, but with all three axial plungers shown in extended position during part of the biaxial CM
casting process (similar to the corresponding parts of the apparatus shown in Figures 7, 8 and 9).
Figure 20 is a schematic illus-tration of another modified biaxial CM casting apparatus for use in a biaxial CM
casting process to make biaxial CM "T-blocks" shown in Figure 24 according to the present inventions. Figure 20 shows a top view of the mold box and mold sides and a cross-section of the mold core assemblies taken at the level of the central axes of the axial plungers of said mold core assemblies in Figure 20~
Figure 21 is a top plan and cross-sectional view of -the mold box and mold core assemblies similar to Figure 20 but showing all of axial plungers of the mold core assemblies in retracted position (instead of their being in extended position as shown in Figure 20).
Figure 22 is a vertical section of the modified embodiment for making biaxial CM T-blocks shown in Figures 20 and 21, taken along line 22-22 in Figure 20. Figure 22 shows the embodiment of Figures 20-23 wi-th the axial plungers in extended position in a phase of operation for the embodiment of Figures 20-23 analogous -to the phase of operation shown in Figure 19 for the embodiment of Figures 18-19 descrlbed below.
Figure 23 is a vertical section of the modified embodiment shown in Figures 20-22 taken along line 23-23 in Figure 21. Figure 23 shows the embodiment of Figures 20-23 in a phase of operation for said embodiment similar to the phase of operation shown in Figure 18 for the embodiment of Figures 13-19.
Figure 24 shows a modified biaxially cast CM "T-block"
which is generally like the above-described biaxially cast CM
block of Figure 5A but which has openings in one end web and the central web extending normal to the axis of casting, and which also has two aligned openings in the block face shells communicating with one of the twin cavities of the CM block and thus with said openings in said webs and with the other twin cavity of the T-block. Also, the T-block shown in Figure 24 can be used to provide a "T-wall-connection" as illustrated in Figure 24 when such T-block is used with two adjoining CM blocks 30b of the kind shown in Figure 5A at the ends of two intersecting walls made with such CM blocks 30b.
Figure 25 is a schematic illustration of another modified biaxial CM casting appara-tus for use in a biaxial CM
casting process to make biaxial CM "L-blocks" shown in Figure 29 according to the present inventions. Figure 25 shows a top view of the mold box and mold sides and a cross-sec-tion of the mold core assemblies taken at the level of the central axes of the axial plungers of said mold core assemblies in Figure 25.
Figure 26 is a top plan and cross-sectional view of the mold box and mold core assemblies similar to Figure 25 but showing all of axial plungers of the mold core assemblies in re-tracted position (instead of their being in extended position as shown in Figure 25).

Figure 27 is a vertical section of the modified embodiment for making biaxial CM L-blocks which :is shown in Figures 25 and 26, taken along line 27-27 in Figure 25. Figure 27 shows -the embodiment of Figures 25-28 with the axial plungers in extended position in a phase of operation for the embodiment of Figures 25-28 analogous to the phase of operation shown in Figure 19 for the embodiment of Figures 18-19 described below.
Figure 28 is a vertical section of the modified ~.
embodiment shown in Figures 25-27 taken along line 28-28 in Figure 26. Figure 28 shows the embodiment of Figures 25-28 in a phase of operation for said embodiment similar to the phase of operation shown in Figure 18 for the embodiment of Figures 18-19.
Figure 29 shows a modified biaxially cast CM "L-block"
which is generally like the above-described biaxially cast CM
block of Figure 5A but which has openings in one end web and the central web extending normal to the axis of casting, and which also has one opening in one of the block face shells communicating with one of the twin cavities of the CM block and thus with said openings in said webs and with the other twin cavity of the L-block. Also, the L-block shown in Figure 29 can be used to provide a "corner connection" as illustrated in Figure 29 when such L-block is used with one adjoining CM block 30b of the kind shown in Figure 5A at the end of a row of such CM blocks 30b.
Figure 30 is a perspective view of a "biaxial maintenance module" used for cleaning the axial plungers of the biaxial CM mold core system shown in Figures 13 and 14 at the end ~of a particular run or working day or the like.
Figure 31 is an end elevation view of the biaxial maintenance module shown in Figure 30.
Figure 32 is a longitudinal sectional view of the biaxial maintenance module shown in Figures 30 and 31, taken along line 32-32 in Figure 31.

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In the accompanying drawings, like parts are identified with like numerals. Modified components or parts are sometimes identified by like numerals plus subscripts as below set forth to conveniently indicate similarities and diEferences between various embodiments.
Reference is now made particularly to Figure 1 which shows a conventional twin-cavity CM block generally indicated at 30. CM
block 30 comprises two relatively elongated substantially parallel face shells 31 which are interconnected by two laterally extending end webs 32 and a center web 34. The two face shells 31 and the three webs 32,34 form two cavities 35 which extend through the CM block 30 from the top 37 to the bottom 38 thereof in the direction of the axis of casting of conventional CM block ~30 in a conventional commercially available CM block casting machine. Each of block cavities 35 has a substantially rectangular cross-section, and both cavities 35 have substantially the same dimensions. Each of face shells 31 are of like thickness, and each of the three webs 32,34 are of like thickness. (Representative dimensions of the conventional twin-cavity CM block 30 and its components are the same or substantially -the same as dimensions of corresponding components ~of the below-described novel biaxially cast CM block generally indicated at 30a in Figures 2-5.) Reference is now made particularly to Figures 2-5 which show a novel biaxially cast twin-cavity CM block generally indicated at 30a. Biaxially cast CM block 30a comprises longitudinally extending substantially parallel face shells 31 which are interconnected by two laterally extending end webs 32a and a center web 34a. The face shells 31 and the three webs 32a,34a form two cavities 35 which extend through the block 30a from the top 37 to the bottom 38 thereof in the direction of the flow of CM material during casting of biaxially cast CM block 30a. For a suitable and typical biaxially cast twin-cavity CM block made _r ~ ~3~73~

according to the present invention, the various ~omina1 dimenslons of components oE C~ block 30a woulcl be subs-tantially as follows: overall length of face shells 31 in direction perpendicular to the axis of casting is 15.625 inches; thickness of face shells 31 is 1.25 inches; overall block width measured between the two outer surfaces of face shells 31 is 7.625 inches;
transverse distance between the inside surfaces of face shells 31, and thus the transverse dimension of each cavity 35, is 5.125 inches; each of end webs 32a is inset from ends 39 of the hlock 0.75 inches; the thickness of each of webs 32a and 34a is 1 inch;
and the distance between each end web 32a and center web 34a, and thus the longitudinal dimension of each cavity 35, is 5.56 inches; the height of the block 30a between top 37 and bottom 38 is 7.625 inches.
The biaxially cast CM block 30a of Figures 2-5 differs from the conventional CM block 30 of Figure 1 in that there are openings or apertures 40 extending through each of the end webs 32a and the center web 34a with -the axis of each opening 40 being subs-tantially normal to the direction of material flow during casting (i.e., the "axis of cas-ting"). The openings 40 in the webs 32a and 34a are made by varying the mold aperture during casting and timing such variation of mold aperture in such a way as to result in variation of the shape of the CM bloc]c 30a by providing openings 40 which are formed normal to the axis of casting without a secondary manufacturing operation, as further below explained. The openings 40 in webs 32a and 34a of biaxially cast CM block 30a having typical dimensions above-described may have a diameter of about 3 to 4 inches. The center of openings 40 is located on, or substantially on, the block's vertical centerline VCL which is midway between the outer surfaces of block face shells 31; and the center of openings 40 is also located at or slightly below the block's horizontal centerline HCL which is at the vertical midpoin-t of the block ~ ~'773~

between top 37 and bottom 33. The configuration, size and location of biaxially cast openings 40 must be such as to avoid problems of inducing cracking in the manufac-ture of biaxially cast CM blocks 30a. The openings 40 of CM block 30a are likely to be circular as shown in Figures 2~5, and loca-ted and sized as hereinabove set forth. The configuration, size and location of biaxially cast openings such as 40 are a function of the dimensions of the biaxially cast CM block and its components and of the size, shape and location of such openings. It is possible to use different non-circular configurations for opening 40, and different sizes and locations for such openings in relation to block centerlines HCL and VCL, as will be apparent to those skilled in the art in light of the disclosure herein.
Reference is now made to Figure SA described above showing a biaxially cast CM block 30b which is a modification of biaxially cast CM block 30a shown in Figures 2-5 and described above with reference thereto. The biaxially cast CM block 30a of Figures 2-5 is an "open end block" having a pair of inset recesses 33 at opposite ends of block 30b made by inserting end cores in the mold box (such as shown at 54 in below-described Figure 15); this is done in like manner as providing like inset recesses 33 at opposite ends of a conventional open end block such as shown at 30 in Figure 1. However, by not using such end cores in the mold box, the biaxially cast CM block 30b will have a modified configura-tion as shown in Figure 5A differing from above-described CM block 30a shown in Figures 2-5. The difference between biaxially cast CM block 30b of Figure 5A as compared to biaxially cast CM block 30a is that the end webs 32b have their outer surfaces aligned with block ends 39, and the longitudinally extending dimension of cavities 35b is correspondingly longer than that of cavity 35 in CM block 30a shown in Figures 2-5 and above described. Otherwise, components of CM block 30b shown in Figure 5A identified by like numerals in Figure 5A as in Figures 2-5 are oE like configuration and size as corresponding like identified components ln Figures 2-5 excepting that -the longitudinal dimension of each cavity 35b is 6.31 inches in block 30b of Figures 2-5 (instead of 5.56 inches as in block 30a of Figures 2-5).
Reference is now made to Figures 6-12 and 13-15. The biaxial CM mold core system generally indicated by numeral 41 includes a pair of mold core assernblies generally indicated at 42 and 44 respectively, plus core bar assembly and mounting means generally indicated at 46 for installing the system 41 in a commercially available CM block casting machine generally indicated at 48, plus air supply means generally indicated at 50 for pneumatically operating the mold core assemblies 42 and 44 of biaxial CM mold core system 41.
The CM casting machine 48 includes a four-sided mold box generally indicated a-t 52 which has four vertically extending sides 54 disposed substantially at right angles to each other.
The CM casting machine 48 also includes a compression and stripper shoe ("compression/stripper shoe") generally indicated at 56, a materials feed tray generally indicated at 58, and means for raising a pallet 60 to form the bottom of the mold for casting a CM block as generally known in the art and as hereinafter discussed. (It is noted that numeral 52 is sometimes used to refer to such mold as well as to -the mold box itself.) Referring especially to Figures 13-15 and 17, each of mold core assemblies 42 and 44 includes a generally rectangular shaped mold core 49 having a pair of opposi-te vertically disposed like planar side walls 51, plus a pair of opposite vertically disposed like planar end walls 53 and 53a, plus a horizontally disposed planar top end wall 55, and an open bottom 57. The mold cores 49 are similar to conventional mold cores used to make conventional twin-cavity CM blocks such as above-described CM block 30 shown in Figure l; but each of mold cores 49 is modified by cutting 7~

axially aligned circular apertures 59 ln opposite sides 53 and 53a thereof. A cylindrical assembly sleeve 62 is disposed within each mold core 49 and has its opposite ends mounted in apertures 59 in opposed mold core side walls 53 and 53a, as further explained below. An "inner" axially reciprocating plunger 7 ndicated at 64 is mounted in one end of cylinder 62 in each mold core assembly 42 and 44 in such manner so that (i) each plunger 64 can be retracted inside of adjacent walls 53a of its mold core ~9 as shown at the right of Figure 13 and diagrammatically illustrated in Figures 6, 9, 11 and 12; and so that (ii) such plungers 64 can project outside of said mold core walls 53a as shown at the left in Figure 13 and diagrammatically illustrated in Figures 6-12. Another somewhat longer "outer" axially reciprocating plunger indicated at 66 is mounted in the other end of cylinder 62 of each mold core assembly 42 and 44 so that (i) each plunger 66 can be retracted inside of adjacent wall 53 of its mold core 49 as shown at the right of Figure 13 and diagrammatically illustrated in Figures 6, 9, 11 and 12; and so that (ii) plungers 66 can project outside of said walls 53 as shown at the left in Figure 13 and diagrammatically illustrated in Figures 6-12. It is noted tha-t the construction and mode of operation of the axial plungers 64 and 66 are the same in each of mold core assemblies 42 and 44. However, for convenience of description of the invention herein, the mold core assembly 42 is shown at the left of Figure 13 with both of its axial plungers 64 and 66 in extended position projecting outside of walls 53,53a of the mold core 49 in position for certain phases of -the biaxial CM
casting process; whereas the mold core assembly 44 is shown in the right of Figure 13 with its axial plungers 64 and 66 in retracted position with both said plungers being disposed inside the walls 53,53a of the mold core 49 for other phases of the biaxial CM casting cycle.

P7'34 In the preferred embodiment, the axial plungers 64 and 66 are energized to extend them as shown in the mold core assembly 42 in Figure 13 (and in Figures 7, ~3 and 9) and to retract them as shown in the mold core assembly 44 of ~'igure 13 (and in Figures 6 and 11) by compressed air means as explained in detail below. However, it is noted that axial plungers like 64 and 66 of equivalent mold core assemblies like 42 and 44 could be analogously energized to extend and retract such plungers in similar manner by equivalent mechanical means, electromechanical means, hydraulic means, or a combination of the foregoing, any one or more of which may also be combined with compressed air means, as will be apparent to one skilled in the art in light of the disclosure herein.
Further details of construction and mode of operation of the biaxial CM mold core system 41, mold core assemblies 42 and 44 and their compressed air operated axial plungers 64 and 66, plus related components are set forth below.
Reference is now made particularly to the schematic or diagrammatic drawings of Figures 6-12 which show components of a biaxial CM cas-ting apparatus in various phases of a biaxial CM
casting process for making biaxial CM blocks like 30b (or 30a, using end cores) by utilizing the present inventions disclosed and claimed herein.
Referring to Figure 6, this is a schematic or diagrammatic illustration showing a biaxial CM mold core system 41 installed in the mold box 52 of the CM casting machine. The sides 53 of mold core assemblies 42 and 44 are disposed adjacent to, but suitably spaced from the two shorter sides 54 of mold box 52; and the sides 51 of mold core assemblies 42 and 44 are disposed adjacent to, but suitably spaced from the two longer sides 54a of the mold box 52. (See also Figure 15.) The other sides 53a of each mold core 49 of mold core assemblies 42 and 44 are inwardly disposed adjacent to but spaced from each other a suitable r ~.2~73~

distance. As shown in Figure 6, each of the shorter and loncJer axial plungers 64 and 66 of mold assemblies ~2 and 44 ls wholly re-tracted within the side walls 53 and 53a of i-ts mold core 49.
Figure 6 shows a phase of operation of the biaxial CM casting apparatus and a step in the biaxial CM casting method according to this invention wherein the feed -tray 58 containing the semifluid CM mix is off to the side of the mold 52, the compression/stripper shoe 56 is being moved on its way up to provide access for the feed tray 58 to the mold 52 and a conventional bottom pallet 60 is being moved upward to form the bottom of the mold 52.
Referring now particularly to Figure 7, this is a schematic or diagrammatic illustration of the biaxial CM casting apparatus components shown in Figure 6, but showing such components in a subsequent phase of operation to carry out the biaxial CM casting process according to this invention. In this phase, the bottom pallet 60 is in place -to form the bottom of the mold 52, and the ~compression/stripper shoe 56 is above the level of the feed tray 58 which is moving into position over the mold box 52 for purposes of feeding the semifluid CM mix into mold 52. In this iphase, all axial plungers 64 and 66 are caused by compressed air ~to projec-t in extended position from the mold cores 49 so that the ends 67 of the longer axial plungers 66 abut against adjacent side walls 54 of the mold box 52 and the ends 65 of the shorter axial plunger 64 abut against each other as shown in Figure 7.
Reference is now made particularly to Figure 8 which is a similar schema-tic illustration of the apparatus components shown in Figures 6 and 7, but showing such components in another subsequent phase of operation to carxy out the biaxial CM cas-ting process according to this invention. In this phase, semifluid CM
mix shown at 70 is fed into the cavity of mold 52 while said ~.3'77~3~

a~ial plungers 64 and 66 are stiLl extended from the mold core assemblies 42 and 44 as shown in Figure 7 and explained above with reference to Figure 7.
Reference is now made particularly to Figure 9 which is a similar schematic illustration of apparatus componen-ts shown in Figure 8 but showing still another subsequent phase of the biaxial CM casting process of this invention. In -this phase, the feed tray 58 has been laterally withdrawn from its position over the mold 52 permitting the compression/stripper shoe 56 to come down and compress the CM mix 70 in the mold 52 as vibration of the mold proceeds by conventional means incorporated in CM
casting machine 48. During this phase of operation said axial plungers 64 and 66 remain extended from the mold cores 42 and 44 as shown in Figures 9, and shown and described above with reference to Flgures 7 and 8. Hence, in the phases of operation shown in Figures 9 and 8 the extended axial plungers 66 have their ends 67 abutting adjacent mold box side walls 54 and axially extending plungers 64 have their ends 65 abu-tting each o-ther so as to prevent CM mix 70 from filling in the spaces in mold 52 thus occupied by the por-tions of said extended plungers 64 and 66 projecting from both mold cores 49, as will be apparent from Figures 9 and 8 and the foregoing description -thereof. This causes the formation of openings 40 in end webs 32b and in center web 34a of the biaxially cast CM block 32b shown in Figure 5A and described above with reference to tha-t figure plus Figures 2-5.
(This is in contrast to conventionally cast twin-cavity CM blocks 30 such as shown in Figure 1, which have solid end and center webs due to use of conventional mold cores that do not incorporate axial plungers 64 and 66, or o-ther equivalent means.) Reference is now made particularly to Figure 10 which is a schem~-tic illustration of apparatus components similar to that of Figure 9, but shows a next phase of apparatus operation for carrying out the biaxial CM casting process according to this ~ ~'773~1L

invention. In this phase, -the axial plungers 64 and 66 are in -the process of being re-tracted by compressed air to dispose said plungers 64 and 66 inside the walls of the mold cores 49 after ~completion of the block compression phase of the process described above with reference -to Figure 9 (and Figure 8)u Reference is now made particularly to Figure 11 which is a schematic illustration similar to Figure 10 but shows another subsequent phase of apparatus operation to carry out the biaxial CM block casting process of this invention. In this phase, the axial plungers 64 and 66 are fully retracted to within the side walls of the mold cores 49, whereby the compressed CM material formed into CM block 30b having three web openings 40 can be and ls stripped from the cavity of mold 52 by simultaneous downward motion of the compression/stripper shoe 56 and bo-ttom pallet 60.
Reference is now made particularly to Figure 12 which is a schematic illustration of various apparatus components shown in Figure 11, but shows still another subsequent phase of apparatus operation to carry out the biaxial CM casting process according to this invention. In this phase, the compression/stripper shoe 56 returns upward past -the mold core assemblies 42 and 44 and their axial plungers 64 and 66 which are retracted within the side walls of the mold cores 49, while the newly made biaxially cast CM block 30b is being ejected on its individual pallet 60 onto a conveyor.
After the compression/stripper shoe 56 moves upwardly out of and above the mold 52 the above-discussed steps of Figures 6 through 12 then may be and are repeated to carry out the next cycle for molding the next CM block 30b in like manner as described above with reference to Figures 6 through 12 in light of Figures 13-17 and description thereof further amplified below.

Reference is now made particularly to Figure 13, together with Figures 14-17, for further detailed description of the biaxial CM mold core system generally indicated at 41, the like 4 r 3'7~734 mold core assemblies generally indicated at 42 and 44, and the core bar and mounting assembly generally indica-ted at 46. The core bar assembly and mounting system includes a conventional-type commercially available core bar assembly comprising an elongated core bar 72 which has a confi.guration as shown in Figures 13-15 and is welded to the top end wall 45 of each of mold cores 49 (core bar 72 is usually made from high strength steel about one-half inch thick). Core bar 72 has a pair of mounting brackets 74 welded to its ends and extending perpendicular to the longi-tudinal axis of core bar 72. Each of mounting brackets 74 is provided with a pair of holes 75 for receiving four machine screws 76 to lock the CM mold core system 41 in place within mold box 52 to provide a biaxial CM casting mold for carring out the biaxial CM casting process according to the present inventions.
Reference is now made particularly to Figure 13 (and also Figures 14 and 17). As previously noted, mold cores 49 are like conventional commonly available mold cores for commercially available CM casting machines excepting that mold cores 49 are modified by cutting axially aligned circular apertures 59 in opposite sides 53 and 53a of each mold core 49. It is noted that, like in conventional mold cores, -the sides 51, 53 and 53a of mold core 49 are disposed at a slight angle toward the central longitudinal axis of mold core 49 whereby the bottom edge of each of said mold core walls at the bottom opening 57 of mold core 49 is disposed a slight distance closer to said central longitudinal mold core axis than the top portion of said side walls of mold core 49 which join with the top end walls 55 thereof. For example (as in a typical conventional mold core), the bottom edges of said side walls of each mold core 49 will be each disposed closer to the mold core's longitudinal central axis than the top edges of said side walls by about one-eighth inch. The sides of each mold core 49 (like in conventional mold cores) are r ~37~

disposed at such a slight angle to the mold core's central axis to facili-tate stripping of t~le compressed CM block such as shown at 30b in Figures 5A (or block 30a of Figures 2-5) after compression of the CM block ao as to more readily remove the Inewly formed CM block from the mold and the casting machine.
i¦ Reference is now made especially to Figure 13 (and Figures 16-17) for detailed description of mold core assemblies generally indicated by numerals 42 and 44. As previously noted, for convenience in disclosure of the invention herein, mold core assemblies 42 and 44 are the same in construction and mode of operation, but mold core assembly 42 is shown at the left of Figure 13 with plungers 64 and 66 thereof extended, whereas mold core assembly 44 is shown at the right of Figure 13 with plungers 64 and 68 retracted. It also is noted that, for convenience in disclosure of the invention herein, certain features of said like mold core assemblies 42 and 44 are shown in the mold core ;assembly 42 at the left of Figure 13 but are not shown in the mold core assembly 44 at the righ-t of Figure 13, and vice versa.
(Features within the scope of the preceding sentence are noted in description of mold core assemblies 42 and 44 with reference to Figure 13.) It is further noted that, for convenience of disclosure of the invention herein, some features of each of like mold core assemblies 42 and 44 are shown in the section drawings of Figure 13 in the same plane, whereas in actual construction some such features are not in the same plane but are angularly or otherwise displaced with respect to the longitudinal axis of cylindrical assembly sleeve 62. (Features within the scope of ;the preceding sentence are noted in description of mold core assemblies 42 and 44 with reference to Figure 13.) Still referring especially to Figure 13, there is centrally ~disposed within cylindrical assembly sleeve 62 an elongated cylindrical manifold member generally indicated at 78 which extends through the central aperture of an annular-shaped ring ~ ~773~

generally indicated at 80. Ring 80 supports manifo:ld mernber 78 and i-ts related components; manifold 78 and ring 80 are in turn supported within the cylindrical assembly sleeve 62 (some-times called "assembly cylinder 62" or "plungers assembly cylinder 62"). When assembled, cylinder 62, cylindrical manifold member 78 and annular-shaped manifold supporting ring 80 have substantially coincident longitudinal central axes.
Referring especially to like mold core assemblies 42 and 44 in Figure 13, the annular manifold support ring 80 is secured to the assembly cylinder 62 in the interior thereof by a plurality of machine screws like 81 extending through apertures like 82 in the wall of assembly cylinder 62 and respectively threaded into a plurality of drilled and threaded holes like 84 which extend radially into annular ring 80 from its outer periphery. In a typical embodiment, annular ring 80 is secured to assembly cylinder 62 by -three similar machine screws like 81 which are threaded into three similar holes like 84 as shown in Figure 13, and are located in the same plane normal to the longitudinal axis of assembly cylinder 62 and annular ring 80; and each of the other two screws like 81 are spaced at an angle of 90 degrees from screw 81 shown in Figure 13 (such other two screws are no-t shown in the drawing).
Still referring to Figure 13 (and especially to the mold 'core assembly 42 at the left of that figure for convenient description), manifold member 78 which extends through and is supported in the central aperture 83 of annular ring 80 also is laterally secured to ring 80 by a pair of like retaining rings 86 held in circular recessed grooves extending into the outer periphery of manifold member 78 on opposite sides of manifold ;support ring 80. The manifold member 78 is provided at each of its opposite ends with a reduced diameter hub 85 which is externally threaded at 35a. An annular stationary piston member generally indicated at 87 is secured to each of the opposite ends 7~73~

of maniEold member 78 by means of threads :in the central aperture 88 of piston members 87 mating with -threads 85a on each of hubs 85 at the opposite ends of manifold member 78. Each stationary piston member 87 is provided on its ou-ter cylindrical periphery with an annular recessed groove 89 in which there is mounted any suitable commercially available annular sealing ring (or rings) shown at 90. Each stationary piston member 87 also is provided on its outer cylindrical periphery with an annular flanged section 91 which has an annular planar end 92 disposed perpendicular to the longitudinal axis of cylindrical stationary piston 87. The axis of stationary piston 87 is coincident with the above-described axes of assembly cylinder 62, ring 80, and manifold member 78.
Still referring to Figure 13 (and especially to the mold core assembly 42 at the left thereof for convenient description), it is noted that cylindrical axial plunyers 64 and 66 in each of mold core assemblies 42 and 44 are of like configuration excepting that axial plungers 66 are longer than axial plungers 64 in the direction of their longitudinal axis. Also axial plungers 64 and 66 are mounted on their respective coacting stationary pistons 87 in the same way and operate in relation thereto in like manner as herein described. Each axial plunger ~64 is provided with an internal hollow cylindrical portion 93, ;and each axial plunger 66 is provided with an internal hollow cylindrical portion 93a which is like said portion 93 of axial plunger 64 excepting that 93a is longer than 93. The open end of each of cylindrical portions 93 and 93a of axial plungers 64 and 66 is provided with an internal cylindrical step section 94 which in turn is provided with an internally recessed annular groove 95 near the open ends of hollow cylindrical portions 93 and 93a of axial plungers 64 and 66 respectively. An annular ring 96 is moun-ted in internally stepped section 94 of each of axial plungers 64 and 66; and each said annular ring 96 is secured with 3 ~377;~

one flat side thereof abutting annular face surface 92 on the end ~lof cylinder :~lange por-tion 91 of each stationary piston 87, by , means of retaining rings 97 disposed in said annular grooves 95.

" - i jlEach of said annular rings 96 is provided with a groove 98 on its ,lexterior cylindrical surface and with a groove 99 on its interior cylindrical surface 97; and suitable commercially available sealing rings 100 are moun-ted in each of said grooves 98 and 99.
Still referring to Figure 13 (and especially to mold core assembly 42 at the left thereof for convenient description), lannular grooves 102 are provided adjacent opposite ends of each assembly cylinder 62 in the interior cylindrical surEace 103 of cylinder 62. Sweeper gaskets 104 are provided in each of said grooves 102 and each gasket engages the exterior cylindrical , surface of associated axial plungers 64 and 66. Referring now also to Figures 9-11, sweeper gaskets 104 are made of any suitable commercially available material and size so that when plungers 64 and 66 have been extended and exposed to CM mix 70 as shown in Figure 9, and said plungers are then retracted to inside the mold cores 49 as shown in Figures 10 and 11, the sweeper gaskets 104 will wipe particles of CM mix off the cylindrical exteriors of plungers 64 and 66.
At least the exterior of axial plungers 64 and 66 including their respective ends 65 and 67 are coated with a sufficient thickness of a commercially available hard and abrasion-resistant chromium-steel alloy or like suitable material. (As a practical matter, such alloy coating is generally applied electrochemically whereby all surfaces of axial plungers 64 and 66 will be thus coated with such metal alloy.) At least the in-terior surface 103 of each assembly cylinder 62 and the outer edge surface 105 thereof are similarly coated with an adequate thickness of a commercially available hard and abrasion-resistant metal such as chromium-steel alloy or like sui-table material. (Again, for practical production reasons all surfaces of the assembly 73~3L

cylinder 62 may be coated with such metal alloy.) The con~nercially availahle alloy (or alloys) used for coating the interior surface 103 of assembly cylinder 62 and the exterior surfaces 106 of axial plungers 64 and 66 is not only selected for I quality of hardness and resistance to abrasion, but is also selected for anti-galling properties so as to provide a sel.f-lubricating effect between said surfaces of assembly cylinders 62 and axial plungers 64 and 66. By specially coating cylindrical assembly sleeve 62 and plungers 64 and 66, as above-discussed, the axial plungers sub-assembly generally indicated at 45 ,(comprising assembly sleeve 62, annular ring 80, elongated .manifold member 78, sta-tionary piston 87, axial plungers 64 and 66, and rela-ted components described with specific reference to Figure 13) will generally have a useful life of three to five times the useful life of core members 49 in typical commercial operations using biaxial CM casting apparatus and method inventions disclosed herein. Therefore, the axial plunger sub-¦assembly 45 may be made and sold by commercial sources differing from the comrnercial sources providing the core bar assembly 46which will usually also supply the mold cores 49.
il Referring now particularly to Figures 13 and 16, each of like manifold members 78 of mold core assemblies 42 and 44 is I provided with a pair of drilled holes 108 and 109 extending longitudinally through manifold member 78 from end to end, spaced , from and substantially parallel to the axis of member 78. Each manifold member 78 is a~so provided with a pair of drilled holes 110 and 112 extending inwardly from the outer periphery of manifold member 78 so that hole 110 intersec-ts said longitudinally extending hole 108 in manifold member 78, and hole 112 intersects longitudinally extending hole 109 in manifold member 78. Also each manifold member 78 is provided near each ~opposite end thereof with a pair of drilled holes 114 and 116 ex-tending inward from the outer periphery of manifold member 78 and intersecting said long:Ltudinally extending hole 108 in each . manifold member 78. Also, the opposite ends of hole 108 in each manifold member 78 (bu-t not hole 109 thereof) are sealed by plugs , shown at 113 in mold core assembly 42 at the left of Figure 13.
;Referring especially now to mold core assembly 42 at the left of Figure 13, said holes 114 and 116 are located adjacent each of stationary pistons 87 at the opposite ends of manifold member 78 so that compressed air will pass from end-sealed manifold hole 108 through holes 114 and 116 to the sealed-off space 118 between the stationary pi.ston 87 and -the sealed annular ring 96 secured to each of axial plungers 64 and 66. As a result, compressed air injected into the sealed-off spaces 118 via manifold hole 108 and said holes 114 and 116 will apply positive force to axial plungers 64 and 66 causing them to move from the extended position shown in mold core assembly 42 at the left of Figure 13 to the fully retracted position of plungers 64 and 66 shown in the mold core assembly 44 at the right of Figure 13. To cause i plungers 64 and 66 to extend, compressed air injected via manifold member hole 109 -through the open ends thereof into spaces 117 and 119 of plungers 64 and 66 will apply positive force to the axial plungers 64 and 66 causing them to move from ,retracted position shown in rnold core assembly 44 at the right in Figure 13 to the fully extended position of plungers 64 and 66 shown in the mol.d core assembly 42 illustrated at the left of Figure 13.
Still referring particularly to Figures 13 and 16, a top portion of ring 80 is milled to provide a recessed cavity 120 having a bottom surface 122 which will be disposed substantially horizontally when the plungers sub-assembly 45 is assembled in mold core 49. A pair of holes llOa and 112a are drilled in ring 80 inwardly from surface 122 of recess 120 in ring 80 so that when each ring 80 is assembled on its associated manifold member 78, said hole llOa in ring 80 is a continua-tion of hole 110 in 73~

member 78 and said hole 112a in ring 80 is a continuation of hole 112 ln member 78. Each cylindrical assembly sleeve 62 is provided with drilled ~loles llOb and 112b which are respectively substantially axially aligned with said holes llO+llOa and 112+112a. The top wall 55 of each mold core 49 is provided with drilled holes llOc and 112c which are disposed subs-tantially vertically above holes llOb and llOc in cylindrical assembly sleeve 62. It is noted that holes llOc and 112c are located on opposite sides oE core bar 72.
Referring now to Figure 13 and Figures 14-15, an air ;coupling block 124 is welded or otherwi~e secured to core bar 72 above holes llOc and 112c in mold core 49 of mold core assembly 42; and an air coupling block 126 is similarly secured to core bar 72 above holes llOc and 112c in mold core 49 of mold core assembly 42. Metal tubes 128 of suitable material and size for conducting compressed air are disposed on opposite sides oE core bar 72 and tubes 28 are connected at one end by press-fit or in other suitable manner to air passase holes 130 and 134 drilled in i air coupling blocks 124 and 126 respectively. Each of air tubes ~
128 extends through hole 112c in top pla-te 55 of one of mold Icores 49 and through hole llOb in one of cylindrical assembly sleeves 62 and has its o-ther end press-fitted in the upper enlarged portion of hole 112a in one of annular rings 80. The lower ends of air tubes 128 are also sealed by O-ring 129 and retainer means 131 disposed in recessed cavity 120 in ring 80 inside assembly cylinder sleeve 62. Thus compressed air fed via each coupling block 124 and 126, respectively, through its associated air tube 128 will pass through hole 110 in manifold member 78 and then via longitudinally extending hole 108 through ;! the open ends thereof to operate axial plungers 64 and 66 so that they will extend as elsewhere Xerein explained. Similar metal tubes 132 for conducting compressed air are disposed on opposite sides of core bar 72, and tubes 132 are suitably connected at one ~l2~

end to air passage holes 135 and 1~3 drilled in each o~ air coupling blocks 124 and 126 respectively. Each metal tube 132 extends through a hole llOc in top plate 55 of each mold core 49 and hole llOb in associated cylindrical assembly sleeve 62; and each tube 132 has its other lower end press-fitted in the upper I enlarged portion of step hole llOa in annular ring 80. The lower ! ends of each of air tubes 132 are also sealed by an O-ring (like O-ring 129) and said re-tainer means 131 disposed in recessed cavity 120 in ring 80 inside assembly cylinder sleeve 62. Thus compressed air fed via air coupling blocks 124 and 126 respectively through tubes 132 will pass through hole 110 into longitudinally extending end-plugged hole 108 of each manifold ~member 78 to operate axial plungers 64 and 56 so that they will retract as elsewhere herein explained. Retainer means 131 for O~rings 129 is a plate secured in recess 120 in ring 80 by a 'plurality of screws tnot shown) which are threaded into holes extending inwardly into ring 80 from the bottom of 122 of recess 120 (holes not shown).
Air coupling block 124 is provided with another drilled hole '136 perpendicular to and intersecting hole 130 therein and also extending through to the other side of block 124. Air coupling block 124 is provided with still another hole 138 drilled -therein perpendicular to and intersecting hole 135 in block 124 and also extending to the other side of the block 124. The other air coupling block 126 is provided with a hole 140 drilled therein perpendicular to and intersecting hole 134 to form an air conduit therewith. Air coupling block 126 is also provided with another hole 142 drilled therein extending normal to and intersecting the hole 143 drilled in block 126 to provide an air conduit therethrough. An air tube 148 is similarly suitably connected at opposite ends thereof to the air hole 136 drilled in air coupling block 124 and to the air hole 140 drilled in air coupling block 126. Also, an air tube 150 is sui-tably connec-ted at one of its ~ 7t~

ends to the other end of hole 138 in air couplin~J block 124, and the opposite end of air tube 150 is suitably connected to air hole 142 in air coupling block 126. Air tubing -l44 is connected ;to a source of constant pressure compressed air through a suitable commercially available three-way valve or like suitable means 48v, and is press-fit or otherwise suitably connected at one end in hole 136 in air coupling block 124. Air tube 146 is similarly connected to a constan-t pressure compressed air source and suitable commercially available three-way valve or like suitable means 48v, and is press-fit or otherwise suitably connected in -the slightly enlarged end of hole 138 in air coupling block 124.
When the compressed air control means such as a three-way valve 48v is operated to provide compressed air to conduit 144 from a conventional compressed air source by suitable conventional means like a three-way valve, the compressed air will be supplied at the same time to both axial plunger sub-assemblies 45 of mold core assemblies 42 and 44 since they are connected in parallel to the compressed air source via conduit 144 whereby the plungers 64 and 66 of mold core assemblies 42 and 44 will simultaneously be extended outwardly to the position shown in mold core assembly 42 at the left of Figure 13 and in Figures 7, 8 and 9. More specifically, compressed air from condui-t 144 passes to conduit 128 of mold core assembly 42 and simultaneously to conduit 128 of mold core assembly 44 via tubing 148 interconnecting air couplings 124 and 126. The compressed air passes simultaneously via -tubes 128 to and through holes 112a in ring 80 and 112 in manifold 78 and then through longitudinally ~extending hole 109 in manifold 78 and out through the open ends of hole 109 into the inside portions 117 and 119 of axial plungers 64 and 66, respectively, causing said plungers to extend ~;

~ 37~3~
i . , lunder -the positive force exerted thereon hy compressed air in the ¦ manner described. When the compressed air control means such as a three-way valve 48v is alternatively operated to provide compressed air to conduit 146, compressed air will be provided at the same time to each of mold core assemblies 42 and ~44 simultaneously. In this case, the compressed air from conduit 146 passes via air coupling block 124 to and through tube 132 to mold core assembly 42, while compressed air simultaneously passes from conduit 146 via air coupling 126 -through tubing 150 and air coupling 126 and through air tubing 132 to mold core assembly 44, whereby plungers 64 and 66 will simultaneously be retracted to the position shown in mold core assembly at the right in Figure 13 and in Figures 6, 11 and 12. More specifically, the compressed air simultaneously provided through tubing 132 to each of mold core assemblies 42 and 44 passes through holes llOa in ring 80 and hole 110 in manifold member 78 and then into and through the end-plugged longitudinally ex-tending hole 108 in ¦manifold member 78, and thence through laterally extending passages 114 and 116 into the spaces 118 behind s-tationary pistons 87 so as to apply a force which positively and ¦Isimultaneously retracts all of plungers 64 and 66 in both of the mold core assemblies 42 and 44.
Referring particularly to Figures 13 and 17, the bottom portion of each assembly sleeve 62 and annular ring 80 in each of mold core assemblies 42 and 44 is provided with a pair of communicating slots shown at 152 so as to provide an air passage from the inside to the outside of assembly sleeve 62 in communication wi-th the inner portions of axial plungers 64 and 66 disposed on opposite sides of ring 80 in each of mold core assemblies 92 and 44. Such slots 152 provide passages for ~venting of air from inside sleeve 62 and relief of pressure when ~he axial plungers are operated as herein explairled -to cause axial plungers 64 and 66 to move from rhe extended position shown ' in mold core assembly 42 at the leEt oE Figure 13 to the retracted position shown in mold core assembly 44 at -the right of Figure 13. ', Referring particularly to Figure 13, a ho]e 154 ls drilled in the cylindrical wall of each of the longer axial plungers 66 with said hole 154 having its axis parallel to the axis of ¦ plunger 66; and a smaller vent hole 156 is provided at the end of Ihole 154 extending to the outer end surface 67 of each of !~ .
plungers 66. Like holes 154a and 156a are drilled in the cylindrical wall of each of the shorter axial plungers 64. In each of mold core assemblies 42 and 44, a cylindrical pin 158 is mounted at one end on annular support ring 80 in any suitable manner, e.g., by the end of pin 158 being threaded and secured in a threaded hole in ring 80 (see mold core assembly 42 at the left of Figure 13). The axis of pin 158 is substantially llperpendicular to ring 80 and also is coincident with the axis of ¦Iholes 154,156i and the diameter of pin 158 is less than the I lnside diameter of hole 154. Thus, air may be vented through ¦Iholes 154,156 when axial plunger 66 is retracted from the ~extended position shown in mold core assembly 42 at the left of Figure 13 to the retracted position shown in mold core assembly 44 at the right of Figure 13. The pins 158 have an outer diameter also less than -the inner diameter of outer holes 156 at lthe ends of holes 154 in axial plungers 66 so that the ends of ,pins 158 will extend into holes 156 and thereby clear from said holes any particles of CM mix 70 which may have entered holes 156 during any of the biaxial CM block casting steps shown in any one or more of Figures 8-11 described above. Similar but shorter pins 158a are similarly mounted on opposite sides of ring 80 in each of mold core assemblies 42 and 44, and pins 158a extend into "apertures 154a in the sides of axial plugers 64, with the ends of ;: , pins 158a extending into end apertures 156a when the shorter axial plungers 64 are fully retracted. Pins 158a coact with " .

.r ~l2~ 3~L

holes 154a,156a in the shor-ter axial plungers 64 to vent air when plungers 64 are ~etracted and also to displace any par-ticles of CM mix 70 which may become lodged in the end holes 156a, in like manner as explained above wi-th reference to longer pins 158 and holes 154,156 of longer axial plungers 66. (It is noted that while only pin 158 in mold core assembly 42 is shown mounted on ring 80, it will be apparent from the foregoing discussion that all pins 158 and 158a in mold core assemblies 42 and 44 are similarly mounted on opposite sides of rings 80 in both mold core , assemblies 42 and 44.
! Referring now to Figures 9 and 10 plus 13, after the CM mix 70 is compressed and vibrated to form the CM block 30b as shown ~;in Figure 9 and re-traction of plungers 64 and 66 is s-tarted as shown in Figure 10, there will be resultant substantial negative , pressure and vacuum effect between (i) the ends 67 of longer axial plungers 66 and the sides 54 of the mold box 52 and (ii) j,between the two abutting ends 65 of the shorter axial plungers 64. The holes 154,156 in the longer axial plungers 66 and the holes 154a, 156a in the shorter axial plungers 64 serve to break such negative pressure and vacuum effect between the ends 67 of ~¦plungers 66 and mold walls 54 and be-tween the abutting ends 65 of the plungers 64 when said plungers start to retract as illustrated in Figure 10. Also, when the plungers 64 and 66 are being fully re-tracted after completion of the step shown in Figure 10 and before start of the step shown in Figure 11, the ends of pins 158 and 158a will respectively extend into holes 156 of plungers 66 and into holes 156a of plungers 64 to dislodge particles of CM mix therefrom and thereby clean the ends of holes 154,156 and 154a,156a.

Referring now particularly to mold core 42 at the left of Figure 13 and also to Figure 17, each of biaxial plunger sub-assemblies 45 of each of mold core assemblies 42 and 44 is mounted in its associated mold core 49 by a bracket 160 having a ~2~7~3~

relatively elongated main section 162 and two le~s 164 extending substantially perpendicular from sec-tion 162 as will be apparent from said Figures. The elonga-ted portion 162 of bracket 160 is secured to a bottom portion of assembly sleeve 62 by a pair of screws 166 extending in-to threaded apertures 168 in the main ~portion 162 of bracket 160. Each leg 164 of bracket 160 is provided with a threaded aperture 170 which receives a threaded screw member 172 which is provided with a slot 174 (or equivalent means) to enable turning of screw 172 in threaded aperture 170.
A nut 176 is screwed onto the threads of screw 172 on the inside of bracket legs 164 as shown in said Figures. After the biaxial 'plunger sub-assemblies 45 are mounted in apertures 59 in the walls 53 and 53a of mold core assemblies 42 and 44, respectively, bracket 160 is secured -to the assembly sleeve 62 by means of screws 166 threaded into holes 168, and then the screws 172 plus nuts 176 are adjusted in relation to bracket legs 164 and side !~walls 53 and 53a of the mold core 49 so as to finalize the location o-E each biaxial plunger sub-assembly 45 in relation to ,~side walls 53 and 53a of mold cores 49 and to secure each bracket ,160 firmly in relation to its mold core 49. Each respective biaxial plunger sub-assemblies 45 is thus secured by like bracket ¦Imeans in like manner to the associated mold core 49 of each mold core assembly 42 and 44. It is noted that the slots indicated at f ~152 cut in the underside of each of assembly cylinders 62 and the lower opposite sides of each annular ring 80 (as shown in Figures 13 and 17) will extend laterally beyond the sides of the mounting . bracket 160 as shown particularly in Figure 17 so as to permit the venting of air from the inside of each cylindrical sleeve 62 .;to relieve pressure therefrom particularly when -the axial ~plungers 64 and 66 are retracted, as above discussed.

,,~
~' ~2~3~
-Reference is now made particularly to Figures 13, 16 and 17.
Suitable air tubing of metal or the like generally indicated at 178c is connected -to the compressed air source by means of a suitable commercially available pressure reduction device 48v whereby air is fed at a low pressure through tubing 178c and via air couplings 124 and 126 to and through tubing 178 to each of mold core assemblis 42 and 44. The flexible tubing 178 suitably connected to and extending from the ou-tlet end of air couplings 124 and 126 is passed through an aper-ture 180 in the 'top end surfaces 55 of each of mold cores 49, is "snaked" around the assembly cylinder 62 in each of mold core assemblies 42 and 44, and is connected in series to a pair of nipples 184 which are threaded in apertures in each assembly cylinder 62 so -that air will pass through flexible tubing 178 to the inside of cylinders 62 of each mold core assembly 42 and 44. See especially mold core assembly 44 at the right in Figure 13 and both mold core assemblies 42 and 44 shown in Figure 17. Flexible tubing 178 is connected by nipples 184 in like manner to both mold core assemblies 42 and 44 and operation thereof is the same for both assemblies 42 and 44. When the axial plungers 64 and 66 of the mold core assemblies 42 and 44 are retracted during biaxial CM
block casting process in the steps illustrated in Figures 10 and 11, it is necessary to assure that all axial plungers 64 and 66 are fully retracted so that all parts thereof are totally disposed inside of walls 53 and 53a of the mold cores 49 as shown at the right of Figure 13 and in Figure 11 before the CM block 30b is stripped from the mold 52 by the compression/stripper shoe as shown in Figure 11. The nipples 184 connected to flexible air lines 178 are located so that the aperture in each nipple 184 extending to the inside of assembly sleeve 62 will be blocked off by the "inner ends" of axial plungers 64 and 66 when those plungers are in fully retracted position, as shown particularly in mold core assembly 44 at the right of Figure 13. The nipples 184 in cooperation with their associated alr lines 178 serve as "air sensors" for axial plungers 64 and 66 in each of mold core assemblies 42 and 44 to determine whether each and all said ¦Iplungers 64 and 66 are fully re-tracted to inside mold core 49 as shown in mold core assembly 44 a-t the right of Figure 13. That is because if all said axial plungers 64 and 66 are fully re-tracted there will result a sufficient pre-determined back pressure (e.g., 5 psi or the like) which is measured by a jlsuitable commercially available pressure gauge 48g that is connected to the low pressure line 178c on the input side of air coupling 124 and is mounted on CM casting machine 48 where it can be conveniently observed by the machine operator. Thus, if such back pressure via nipples 184 and air lines 178,178a is above a predetermined psi level, that indicates that the axial plungers 64 and 66 are fully retracted so that the CM block casting operation can be continued. On the other hand, if all the axial plungers 64 and 66 are not fully retrac-ted, air will pass via air lines 178 through nipples 184 into assembly cylinders 62 and out of vents 152 in the underside thereof î and ~this will cause a low and insufficient back pressure reading at the pressure gauge 48g in line 178c on the input side of air coupling 124, thereby indica-ting that one or more of axial plungers 64 and 66 are no-t sufficiently retracted. The machine operator can then intervene to pu-t matters aright by manual operation. Further, such "air sensor" arrangement for deter-mining full retraction of plungers 64 and 66 by means of nipples 184 and air lines 178,178a is also used (i) to discontinue operation of the casting machine 48 if any axial plungers 64 and 66 are not fully re-tracted or (ii) to permit continued operation of the CM casting machine 48 if the axial plungers 64 and 66 are fully retracted, as further described below.

73~

Referring -to Figure ~5, the portion of conventional CM
cas-ting machine 48 shown in that drawing is made from a press-through of a photograph of a Columbia Machine Model 5 made by ilColumbia Machine, Inc., located in Vancouver, Washington ("Columbia"). This model Columbia machine makes one block at a ~time, at the rate of one block about every six seconds.
Columbia, however, also makes similar CM cas-ting machines operating in similar manner but which can produce three, six or even 12 CM blocks at a time (a three-block casting machine is believed most commonly used in -the U.S.A. CM block making industry). Such Columbia machines, exemplified by Columbia Machine Model 5, have both a manual and automatic cycle opera-ting mode. For the automatic cycle operating mode, the casting machine has a control panel incorporating electromechanical control circuitry to operate the machine in a conventional cycle.
In a conventional CM block casting process, conventional mold cores similar to cores 49 but having four planar side walls would be used in a conventional manner well known in the art. The control circuitry of casting machine provides a logic pattern for conventional CM casting whereby: (1) the compression/stripper shoe 56 is lifted upwardly above the level of the feed tray 58 and a pallet 60 is raised to form the bottom of mold 52, analogous to the phase of operation shown in Figure 6; (2) the . I .
feed tray 58 moves in over the mold 52 below the compression/stripper shce 56, analogous to -the phase of operation shown in Figure 7i (3) CM mix 70 is fed into -the cavity of the mold 52 from the feed tray 58, analogous to the phase of operation shown in Figure 8; (4) the feed tray 58 is laterally withdrawn from over the mold 52 permitting the compression/stripper shoe 56 to come down and compress CM mix 70 in the mold 52 as vibration of mold 52 proceeds by conventional means incorporated in CM casting machine 48, analogous to the phase of operation shown in Figure 9; (5) -the compressed CM

~2~ 3~L

material formed into a conventional CM block such as shown at 30 ,in Figure 1 is then stripped from the cavi-ty of the mold 52 by simultaneous downward motion of compression/stripper shoe 56 and the bottom pallet 60, analogous to the phase of operation shown ' in Figure 11; (6) the compression/s-tripper shoe 56 returns upward past the mold cores while the newly made conventional CM block 30 is being ejected on its individual pallet 60 onto a conveyor; (7) after the compression/stripper shoe 56 moves upwardly out of and above the mold 52, the above-discussed s-teps (1) to (6) are then repeated to carry out the next cycle for molding the next conventional block 30 in like manner as just described above ,herein. Note that in such a conventional CM block casting process there is no step corresponding or analogous to that shown in Figure 10.
To use the biaxial casting apparatus and process disclosed herein in a conventional Columbia CM casting machine 48, there is provided a suitable commercially available electromechanical ~! i ' control means 48c for the suitable commercially available three-way valve 48v as part of the compressed air control ,:means so as to alternately supply compressed air from a compressed air source -to conduit 144 whereby such compressed air i passing through tubing 128 to manifold hole 109 will cause axial ! plungers 64 and 66 in both mold core assemblies 42 and 44 to extend simultaneously. Also, said electromechanical compressed air control means 48c is caused to alternatively operate the three-way valve 48v to alternately supply compressed air to conduit 146 and thus via tubes 132 to hole 108 in manifold 78 so as to simultaneousl.y cause retracting of all plungers 64 and 66 ~in mold core assemblies 42 and 44. The electromechanical control means 48c for the three-way valve 48v (or other equivalent con-ventional means) for alternately feeding compressed air from the ~source to input line 144 (to extend all axial plungers 64 and 66) or to input line 146 (to retract all axial plungers 64 and 66) 3~

are appropri~tely -tapped into the electrica:L control circuitry in the control box 48c of -the machine 48 to modify the machine's au-toma-tic opera-tions logic pattern so as to change the machine's ~typical above-discussed conventional molding cyle to the biaxial CM casting cycle shown in Figures 6-12 and fully described above.
Thus the electromechanical means for controlling the three-way valve (or other equivalent means) is tapped into -the control circuitry of casting machine 48 to modify its logic whereby: (a) compressed air is fed to line 146 to simultaneously positively retract axial plungers 64 and 66 in both mold core assemblies 42 and 44 as the compression/stripper shoe 56 is raised to above the feed tray 58 and the pallet mold 60 is raised to form the bottom of the mold 52, as shown in Figure 7; (b) compressed air is then supplied by operation of the three-way valve to input conduit 144 to cause the axial plungers 64 and 66 to be simultaneously positively extended and to remain in such extended position, as shown in Figures 7, 8 and 9 for the phases of the biaxial CM
`casting process shown in said Eigures and described above; (c) the three-way valve is then switched to supply compressed air to input condui-t 146 -to cause the axial plungers 64 and 66 to move to simultaneously positively re-tract after the CM block 30b is formed as shown in Figures 10 and 11, and to maintain said plungers in fully retracted position within the walls of mold cores 49 as shown in Figure 11 before the compression/stripper shoe 56 and pallet 60 are permitted or caused to be moved downward to strip the completed CM block 30b from the mold 52 as shown in Figure 11; (d) the compression/stripper shoe 56 is raised up past the mold cores 49 and the fully retracted axial plungers 64 and 66 disposed inside the walls of mold cores 49 while the just-made CM block 30b is moved -to a conveyor on its pallet 60 and a new pallet 60 is moved in below the mold 52 to provide a new mold bottom; and (e) the CM biaxial mold process and phases thereof shown in Figures 6-12 is thereafter repeated.

,r ~3~7~73~

The portion 178a of the low pressure third air line 178,]78a whlch extends from the input side of the air coupling 124 is connected to a suitable commercially available pressure gauge 48g to indicate to the machine operator whe-ther the back pressure of air at nipples 184 and in lines 178,178a is (1) equal to or greater than a predetermined minimum back pressure (e.g., 5 psi), thereby indicating to the operator that the axial plungers 64 and 66 are fully retracted, or (2) is below such predetermined minimum back pressure, thereby indicating to the operator that one or more of axial plungers 64 and 66 are not fully retracted.
'I
In the latter case (2), the operator can manually stop -the machine 48. However, said line 178c is not only connected to ;such a pressure gauge but also is connected to a pressure-operated switch which is in turn tapped into the control circuitry of the casting machine 48 to operate as a "go-no go"
addition to the machine's control system so that after a CM block 30b has been formed as shown in Figure 9, the machine will not proceed with stripping of the block 30b and removal of the pallet 60 unless all axial plungers 64 and 66 move to fully retracted position as shown in Figure 11 and in assembly 44 at the right of Figure 13. If all axial plungers 64 and 66 are thus fully retracted the thus-modified machine 48 will proceed with the next phase of the block casting cycle involving removal of the CM
block 30b as shown in Figure 11, and then automatically proceed ~with additional CM block making cycles as shown in Figures 6-12 as hereinabove described. However, if all axial plungers 64 and 66 are not fully retracted when they should be (as in Figures 6 and 11) the thus-modified machine 48 will not proceed with the next phase of the biaxial CM casting process; the operator will then determine and fix the problem using manual operation of machine 48.

--~0--4~

~.377;:~

The operating program and logic governing the conventional block-making automatic cycle of machine 48 exempliEied by Columbia Machine Model 5 is shown in Columbia drawing No. D-328-30-52-1 titled "Control Schematic, Model 5 Block Machiné, Stepper Controlled Oscillation". The aforementioed electromechanical controls for operating the three-way valve 48v for alternately supplying air to input conduit 144 to extend all axial plungers 64 and 66 or to input conduit 146 to retract all axial plungers 64 and 66, and the aforementioned pressure-operated switch connected to low pressure inpu-t line 178c are suitably tapped into the control arrangement shown in said Columbia drawing to modify -the logic and operating program governing conventional automatic operation of the casting machine so as to perform automatic operation of the biaxial CM casting process of Figures 6-12 as herein disclosed and particularly described with reference to Figures 6-12 plus Figures 13-17.
As will be apparent to one skilled in the art in light of the disclosure and detailed explanation herein of the biaxial CM
cas-ting apparatus and biaxial CM casting method of the present inventions, although the same are explained by way of example as used in a Columbia Machine Model 5 casting machine having only one mold, such new biaxial casting appara-tus can be installed in like manner in commercially available machines having three molds, six molds or even up to twelve molds by using for such multiple molds an equal number of mold core systems generally indicated at 41 including mold core assemblies 42 and 44 and core bar and mounting assembly 46 (see Figures 13-14).
It is believed that the construction of the biaxial CM block casting apparatus and its mode of operation and functional results according to the present invention will be clear to one skilled in the art from the disclosure hereinabove, particularly with reference to Figures 13-17 and detailed discussion thereof.
It is also believed that the mode of operation of biaxial CM

1 i.
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casting process according to the present inventions and functional results according to the present inventions also will be fully apparent from the detailed description hereinabove with reference to Figures 6-12 in conjunction with Figures 13-17.
Reference is now made -to Figures 18 and 19 which schematically show modified embodiments of above-described mold core assemblies 42 and 44 that are indicated generally , at 42b and 44b. Components of the modified embodiment shown in Figures 18-19 which are the same as corresponding components of the embodiment shown in Figures 13-17 plus Figures 6-12 are identified by like numerals. Components of the modified embodiment of Figures 18-19 which are similar to but changed from components of the embodiment shown in jFigures 13-17 plus Figures 6-12 are identified by the same ¦Inumerals as used in Figures 13-17 and 6-12 plus the letter "b".
~ old core assembly 44b in the embodiment of Figures 18 and 19 is constructed and operated in the same way as mold core assembly 44 shown at the right of Figure 13, excepting ithat mold core assembly 44b has an axial plunger 64b plus an axial plunger 66. The axial plunger 66 in the modified mold core assembly 44b is the same as axial plunger 66 in mold lcore assembly 44 shown in Figure 13. The axial plunger 64b of the embodiment in Figures 18-19 is like the axial plunger ;¦64 in mold core assembly 44 shown in Figure 13; but axial plunger 64b of the embodiment as shown in Figures 18-19 is longer than inner axial plunger 64 in the mold core assembly 44 shown in Figures 13-17 and diagrammatically illustrated in Figures 6-12. The inwardly disposed axial plunger 64b of mold core assembly 44b is sufficiently longer than the inwardly disposed axial plunger 64 of core mold assembly 42 - l;

~3~

in Figure 13 so that when plunger 64b is extended the end 65b thereof will engage the wall 53b of the mold core 49b of mold core assembly 42b. Thus extended plunger 64b will provide a cylindrical end section of plunger 64b which spans the space between wall 53a of mold core assembly 44b and wall 53b of mold core assembly 42b as shown in Figure 19 -- in a manner comparable -to the abutting ends 65 of extended plungers 64 of mold core assemblies 42 and 44 as shown in Figures 7-9 (which are analogous to Figure 19). The mold core assembly 42b in the embodiment of Figures 18-19 is similar to the mold core assembly 42 of the embodiment of Figures 13-17 and Figures 6-12 in that mold core assembly 42b has an axial plunger 66 which is the same in construction and mode of operation as the axial plunger 66 of the mold core assembly 42 shown in Figures 13-17 and Figures 6-12. However the modified embodiment of mold core assembly 42b shown in Figures 18-19 ,differs from the mold core assembly 42 in Figures 13-17 (and illustrated in Figures 6-12) in that mold core assembly 42b in the embodiment of Figures 18-19 has a planar wall 53b ¦(without any apertures such as shown at 59 in wall 53a of mold core assembly 42 at the left of Figure 13). The mold core assembly 42b is built analogously to mold core 42 (and mold core 44) described above in detail with reference to Figures 13-17; but the manifold member in mold core assembly j42b corresponding to manifold 78 of mold core assembly 42 `(and 44) is built with only one stationary piston such as shown at 87 at the left in mold core assembly 42 in Figure 13 and with only one axial plunger 66 (like plunger 66 in mold core assembly 42 in Figure 13). The air supply arrangement for the mold core assembly 44b in the embodiment of Figures 18-19 is like that for the mold core assembly 44 described above with reference to Figures 13-17. However, in the embodiment of Figures 18-19 the manifold in mold core ~1 '3'7~

!assembly 42b correspondlng to manifold 78 ln mold core assembly 42 (at the left of Figure 13) is modified to provide only air conduits for opera-tion of the single axial plunger 66 in mold core assembly 42b. The air supply means for the mold core assembly 42b are generally similar to those for the mold core assembly 42 at the left of Figure 13. However, Isuch air supply means for mold core assembly 42b are connected to only one set of holes in ring 80 and associated holes in the modified manifold to actuate the single plunger 66 to extend outwardly and retract inwardly (similarly to loperation of plunger 66 of the mold core assembly 42 at the left of Figure 13). Further only one nipple 184 is connected to the outer axial sleeve 62 of mold core assembly 42b and ;connected to a flexible air line 178, with nipple 184 disposed adjacen-t the end of axial plunger 66 of mold core assembly 42b when said plunger 66 is in fully retracted position so as to operate as an "air sensor" to indicate full retraction of the axial plunger 66 of mold core assembly 42b in a manner like that described above with reference to mold l!core assembly 42 (and mold core assembly 44) in the embodiment of Figures 13-17 also illustrated in Figures 6-12.
Figure 18 shows the embodiment of Figures 18-19 with the ~axial plungers 66 and 64b fully retracted similarly to retraction of plungers 64 and 66 in the phase of operation shown in Figure 6 for the embodiment of Figures 13-17 (and also analogous to the phases of operation shown in Figures 11 and 12 for the embodiment of Figures 13-17). The embodiment of Figures 18-19 is shown in Figure 19 with the axial plungers 66 and 64b in extended position similarly to extension of plungers 64 and 66 shown in Figure 7 for the embodiment of Figures 13-17 (and also analogous to extended position of said plungers for the phases of operation shown in Figures 8 and 9 for the embodiment of Figures 13-17).

3~

It is believed tha-t the construction of modlfied biaxial CM casting apparatus incorporating modlfied mold core assemblies 42b and ~4b of Fiyures 18-19, and the mode of operation and functional results -thereof according to the present invention will be clear -to one skilled in the art from the disclosure herein particularly in light of the detailed disclosure of Figures 13-17 and Figures 6-12. It is also believed that the mode of operation of biaxial CM
casting process using the modified apparatus embodiment of Figures 18-19 according to the present invention and functional results thereof also will be fully apparent to one skilled in the art from the disclosure herein particularly in light of the detailed description with reference to Figures 6-12 of the apparatus embodiment of Figures 13-17.
;, It is noted that use of the embodiment of Figures 13-17 incorporating two like mold core assemblies 42 and 44 particularly shown in Figures 13-15 each having two axial plungers 64 and 66 is preferable to the modified embodiment of Figure 18-19 for purposes of economical volume production of such mold core assemblies due to the grea-ter commonality of parts of the mold core assemblies 42 and 44 of the ,embodiment of Figures 13-17 as compared to the mold core assemblies 42b and 44b of the embodiment of Figures 18-19.
However, the above-described embodiment of Figures 18-19 will perform well also.
Reference is now made particularly to Figures 20-24 which schematically show another modified embodiment of biaxial CM apparatus and method using modifications of above-described mold core assemblies 42 and 44 that are indicated generally at 42c and 44d. Components of the modified embodiment shown in Figures 20-23 which are the same as corresponding components of the embodiment shown in Figures 13-17 or Figures 18-19 (and Figures 6-12) are _r 7~L

identified by like numerals and let-ters. Components oE the modified embodimen-t of Figures 20-24 which are similar to but changed from components of the embodimen-t shown in Figures 13-17 or Figures 18-19 (and Figures 6-12) are identified by the same numerals as used in Figures 13-17 or Figures 18-lg (and Figures 6-12) plus the letters "c" or "d".
The biaxial CM block cas-ting apparatus shown in Figures 20-23 and the biaxial CM casting process described with reference thereto are used for making a biaxially cast CM
"T-block" such as shown in Figure 24 and described wi-th reference thereto. It is noted the CM T-block shown in Figure 24 may also be referred to as a "triaxially cast" ~M
block, and that the CM casting apparatus and method disclosed in and with reference to Figures 20-23 may also be respectively called a "triaxial CM casting apparatus" and a "triaxial CM casting method."
Mold core assembly 42c in the embodiment of Figures 20-23 is constructed and operated in the same way as mold core assembly 44b shown at the right of Figure 19, as described above (with reference to Figures 13-17), excepting that mold core assembly 42c is inverted left to right compared to mold core assembly 44b shown in Figure 19. The axial plunger 66 in the modified mold core assembly 42c is the same as axial plunger 66 in mold core assembly 42 shown in Figure 13. The axial plunger 64b of mold core assembly 42c is like the axial plunger 64 in mold core assembly 42 shown in Figure 13; but axial plunger 64b of mold core assembly 42c shown in Figures 20-23 is sufficiently longer than inner axial plunger 64 in the mold core assembly 44 shown in Figures 13-17 so that when plunger 64b is extended the end 65b thereof will engage the wall 53d of the mold core 49d of mold core assembly 44d.
Thus extended plunger 64b will provide a cylindrical end section of plunger 64b which spans the space between wall 53a 3~

of mold core assembly 42c and has its end 65b engaging wall 53c of mold core assembly 44d as shown in Figures 20 and 22, in a manner similar to operation of plunger 64b in mold core assembly 42b as shown in Figure 19 and described with reference thereto.
The embodiment of Figures 20-23 incorporates a mold core assembly 44d which is similar in construction and mode of operation to the mold core assembly 44 of the embodiment of Figures 13-17, but modified mold core assembly 44d of Figures 20-23 differs from mold core assembly 44 of Figures 13-17 as follows (referring to Figures 20-23 compared to Figures 13-17): (1) A modified mold core 49d has a pair of opposed spaced planar side walls 53c (which do not have circular apertures 59 therein as in mold core assembly 44 of Figures 13-15); (2) Modified mold core 49d is provided in opposed planar walls 51d thereof with aligned circular apertures 59d;
(3) The mold core sub-assembly (indicated at 45 in Figures 13-15) including assembly cylinder 62 (not shown in Figures 20-24) is mounted and secured in said apertures 59d of mold core 49d in like manner as mold core sub-assembly 45 in the embodiment of Figures 13-15 as above-described; (4) Thus plungers 66d and other related components in their plungers assembly cylinder 62 are disposed (a) perpendicular to like components in mold core assembly 44 in Figures 13-15, and (b) perpendicular to like components of mold core assembly 42c in the embodiment of Figures 20-23; (5) Axial plungers 66d are of equal axial length in mold core assembly 44d in the embodiment of Figures 20-23i and the length of said axial plungers 66d is such that when said plungers are fully extended by compressed air means the ends 67 of plungers 66d will engage the longer mold box side walls indicated at 54' in Figures 25 and 26. [It is noted that longer sides of mold box 52/mold 52 are sometimes indicated by numeral 51l to ~3~7;3~

distinguish said sides from shorter sides Sl oE mold box 52/mold 52.]; ~6) Dimensions of sleeve 62 and other internal components of mold core assemhly 44d will be suitably modified consisten-t with the foregoiny. In the embodiment of Figures 20-24, the compressed air supply and control arrangement for extending and retracting plungers 66 and 64b of mold core assembly 42c and plungers 66d of mold core assembly 44d, plus the air sensors arrangement for assuring full retraction of said plungers, are the same as described above for the embodiment of Figures 13-17.
The compressed air supply means and the air-plunger sensor means for the mold core assemblies 42c and 44d are similar to those for the respective mold core assemblies 42 and 44 in the embodiment of Figures 13-17 as described above with reference to said Figures. The mold cores 42c and 44d are mounted in like manner as mold core assemblies 42 and 44 of Figures 13-17 on a core bar and mounting means such as indicated at 46, 72, 74, 75 in Figures 13-15. The compressed air means and air sensor means for mold core assemblies 42c and 44d are similarly mounted and connected as for assemblies 42 and 44 in Figures 13-17, except tha-t some components like nipples 184 are -turned 90 degrees for mold core assembly 44d in the embodiment of Figures 20-24.
The embodiment of Figures 20-24 is shown in Figures 21 and 23 with the four axial plungers 66, 64b and 66d fully retracted similarly to full retraction of plungers 64 and 66 in the phase of operation shown in Figure 6 for the embodiment of Figures 13-17 (and also analogous to the phases of operation shown in Figures 11 and 12 for the embodiment of Figures 13-17). The embodiment of Figures 20~24 is shown in Figures 22 and 24 with the axial plungers 66, 64b and 66d in extended position similarly to extension of plungers 64 and 66 shown in Figure 7 for the embodiment of Figures 13-17 (and 3~

also analogous to extended position of said plungers for the phases of operation shown in r~`igures 8 and 9 for the embodiment of Figures 13-17).
It is believed that the construction of modified biaxial CM casting apparatus incorporating modified mold core assemblies 42c and 44d of Figures 20-24, and the mode of operation and functional results thereof according to -the present invention will be clear to one skilled in the art from the disclosure herein particularly in light of the ;detailed disclosure of Figures 20-24 plu5 Figures 13-17 and Figures 18-19 with reference to Figures 6-12. It is also believed that the mode of operation of the biaxial CM casting process using the modified apparatus embodiment of Figures 20-24 according to the present invention and functional results thereof also will be fully apparent to one skilled in the art from the disclosure herein particularly in liyht of the detailed description of Figures 20-25 with reference to Figures 6-12 plus Figures 13-17 and Figures 18-19.
Reference is now made particularly to E'igures 24 and 5A
(with reference also to Figure 1, and Figures 2-5). Figure 24 shows an embodiment of biaxially cast CM "T-block" made by using the above-described biaxial CM casting apparatus shown in Figures 20-23 and using a biaxial CM casting method disclosed above with reference to said figures. The T-block made by this modification of biaxial CM casting apparatus and method of Figures 20-23 according to -the present invention is generally indicated at 30c in Figure 24 and comprises a pair of longitudinally extending face shells 31c which are interconnected by laterally ex-tending end web 32b, central web 34a, and end web 32c thereby forming two cavities 35c and 35d which extend through CM T-block 30c from the top to the bottom thereof in the direction of the axis of casting as will be apparent from Figure 24 with reference to the other 3~

Ei~ures mentioned (in the Eirst -two sentences of this paragraph). The end web 32b and -the central web 34a are each provided with openings 40 which are made by varying the mold cavity during casting and timing such varia-tion of said mold cavity in such a way as to vary the shape of the CM block 30c to provide web openings 40 extending in the direction of a second axis normal to the first axis of casting without a secondary manufacturing operation, as herein disclosed. It is noted that end web 32c is not provided with such an opening 40 (in contrast -to biaxially cast CM block 30b shown in Figure 5A and biaxially cast CM block 30a shown in Figures 2-5). The biaxially cast CM T-block 30c is also provided with two substantially aligned openings 40d in opposed portions of the face shells 31c in the region of cavity 35d of block 30c, and said openings 40d extend in the direction of a third axis normal to the axis of casting and also normal to said second axis of openings 40 in webs 32b and 34a. More particularly, said openings 40 in end web 32b and central web 34a are made by varying the mold cavity during casting and -timing such variation by selectively using plungers 66 and 64b of the mold core assembly 42c in extended and retracted positions as shown in Figures 20-23 and above explained.
Said openings 40d in the face shells 31c are made by varying the mold cavi-ty during casting and timing such variation of the mold cavity in such a way as to result in variation of the shape of the CM block 30c to provide openings 40d extending normal to the axis of casting and also normal to said second axis of web openings 40 without any secondary or tertiary manufacturing operation as explained herein. More particularly, said openings 40d in face shells 31c are mde by selectively timed extension and retraction of the axial plungers 66d of mold core assembly 44d of the apparatus 3~7~

disclosed in Figures 20-23 in the operation of said apparatus to perform the biaxial CM casting ~ethod described above with reference -to Figures 20-23.
Referring again now particularly to Figure 24, -the resultant T-block 30c may be joined at its end which has openings 40d in face shells 31c to a pair of biaxially cast CM blocks 30b of configuration such as shown in Figure 5A at the ends of two CM block wall sections made up of CM blocks like 30b (or 30a) so that -the opening 40 in the end web 32b of the adjoining end block 30b of one such CM block wall sections will be in communication with an opening 40d in one of the two face shells 31c of T-block 30c and thus also with cavity 35d of such block 30. Similarly, the opening 40 in the end web 32b of -the other adjoining end block 30b of the other such CM block wall section will be in communication with the second opening 40d in the other face shell 31c and thus also wi-th cavity 35d of T-block 30c. Hence, piping and/or electrical condui-ts or the like can be extended through openings 40 in any of such CM blocks 3Ob into and through one or both face shell openings 40d, cavity 35d and web openings 40 of T-block 30c and then extended in either direc-tion into the perpendicular intersecting walls made up of biaxially cast CM blocks 30b having openings 40 in the end and central webs thereof, as will be apparent to one skilled in the art in light of the showing of CM blocks 30b in conjunction with CM T-block 30c in Figure 24 and explanation thereof herein. It also will be apparen-t that the biaxially cast CM T-block 30c used in conjunction with the biaxially cast CM blocks 30b as shown in Figure 24 and herein explained to provide a "T-wall~connection" will also enable the flow of air through the cavities within said intersecting CM block walls (called a "T-wall-connection") such as illustrated in Figure 24 and herein described.

77~3~
70~5~-1 Re~erence is now made particuLarly to Figures 25-29 whic}l schematlcally show still another moclified embodiments of bia~ial CM apparatus and method using modifications oE above-described mold core assemblies 42 and 44 ln Figures L3-17 and 42b and 43c in Figures l8~]9 that are indicated generally at 42c and 44e. Components of the modified embodiments shown in Figures 25-29 w~ich are the same as corresponding components of the embodiment shown in Figures 13-17 or Figures 18 19 (and Figures ~-12) are identified by like numerals and letters.
Components of the modified embodiment of Figures 25-29 which are similar to but changed from components of the embodiments shown in Figures 13-17 or Figures 18-19 (and Figures 6-12) are identified by the same numerals and letters as used in Figures 13-17 or Figures 18-19 and 6-12 plus the letter "e".
The biaxial CM block cas-ting apparatus shown in Figures 25-28 and the biaxial CM casting process described with reference thereto are used for making a biaxially cast CM
"L-block" or "corner block" such as shown in Figure 29 and described with reEerence thereto. It is noted that the CM
"L-block" shown in Figure 29 may also be called a "triaxially cast" CM block, and tha-t the CM casting apparatus and method disclosed in and with reference to Figures 25-28 may also be called a "triaxial CM casting apparatus" and a "triaxial CM
casting method".
Mold core assembly 42c in the embodiment of Figures 25- 29 is constructed and operated in the same way as mold core assembly 42c shown at the left of Figure 20, with mold core assembly 42c. See above description of mold core assembly 42c with reference to mold core assemblies 42 and 44 in Figures 13-17 and modified mold core assembly 44b of Figures 18-19.
As in the embodiment in Figures 20-23, ;- - 52 ~
:

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when the axial plungers 66 and 64b are ex-tended the end 67 of outer axial plunger 66 will engage the adjacent shorter mold side 54 of mold 52 and the end 6sb of inner axial plunger 64b will engage the wall 53c of the mold core 49e of mold core assembly 44e. Thus extended plunger 64b will provide a cylindrical end section of plunger 64b which spans the space between wall 53a of mold core assembly 42c and has i-ts end 65b engaging wall 53c of mold core assembly 44e as shown in Figures 25 and 27 in a manner like operation of plunger 64b in mold core assembly 42c as shown in Figure 20 and described with reference thereto.
The embodiment of Figures 25-28 incorporates a mold core assembly 44e which is similar to the mold core assembly 44d of the embodiment of Figures 20-23 with respect to mounting and orienta-tion of the plunger sub-assembly in mold core 49e;
but core 49e of mold core assembly 42e differs from mold core 49d and the biaxial plunger sub-assembly of mold core assembly 44e also differs from mold core assembly 44d which has been fully described above in relation to mold core assembly 44 of Figures 13-17. The modified embodiment of mold core assembly 44e shown in Figures 25-28 further differs from the mold core assembly 44d in Figures 20-24 in like manner as single axial plunger of mold core assembly 42b of Figures 18-19 differs in construction and operation from mold core assembly 44 (or 42) of Figures 13-17 as above described with reference to the embodiment of Figures 18-19. In the embodiment of Figures 25-28 (analogous to the embodiment of Figures 18-19) mold core 49 has a planar wall 51 without any aperture such as shown at 59d in wall 51d of mold core assembly 44d at the right of Figures 20 and 21. Like above-described mold core assembly 42b of Figures 18-19, mold core assembly 44b is built analogously to mold core 44 (and mold core 42) described above in detail with reference to Figures 13-17; but, as described with reference to mold core assembly 42b in Figures 18-19, the manifold member in mold core assembly 44e corresponding to manifold 78 of mold core assembly 44 in Figures 13-17 is built with only one s-tationary piston such as shown at 87 in mold core assembly 44 (and 42) in Figure 13 and with only one axial plunger 66d corresponding to plunger 66 in mold core assembly 44 shown in Figures 13-17.
The compressed air supply and air sensor arrangements for the mold core assembly 42c in the embodiment of Figures 25-28 is like that for the mold core assembly 42 described above with reference to Figures 13-17 and with reference to mold core assembly 42c of Figures 20-23. However, as in the above-described mold core assembly 42b in the embodiment of Figures 18-19, the manifold in mold core assembly 44e corresponding to manifold 78 in mold core assembly 44 (at the right of Figure 13) is modified to provide only air conduits for operation of the single axial plunger 66d in mold core assembly 44e. However, the compressed air supply means and the air-plunger sensor means for the mold core assembly 42e are similar to those for the mold core assembly 42c at the left of Figures 18-19 as described above. Tha-t is compressed air supply means for mold core assembly 42e are connected to only one set of holes in the modified manifcld 78 to actuate the single plunger 66d in rela-tion to a single stationary piston to extend plunger 66d outwardly and retract it inwardly (similarly to operation of plunger 66 of mold core assembly 42b in the embodiment of Figures 18-19 described above). Further, as described with reference to mold core assembly 42b in Figures 18-19, only one nipple such as 184 in Figure 13 is connected to mold core assembly 42e and connected to an air line such as 178 with that nipple disposed adjacent the inner end of axial plunger 66d of mold 7~fl~

core assembly of 44e to sense and indicate when said plunger 66d of molcl core assembly ~4e is in fully retracted position in a manner like -that described above with reEerence to mold core assembly 42b of Figures 18-19 compared to mold core assembly 42 (and 44) in the embodiment of Figures 13-17.
The embodiment of Figures 25-28 is shown in Figures 25 and 27 with the three axial plungers 66, 64b and 66d fully retracted similarly to retraction of plungers 64 and 66 in the phase of operation shown in Figure 6 for the embodiment of Figures 13-17 (and also analogous -to the phases of operation shown in Figures 11 and 12 for the embodiment of Figues 13-17). The embodiment of Figures 20-24 is shown in Figures 24 and 26 with the axial plungers 66 and 64b in extended position similarly to extension of plungers 64 and 66 shown in Figure 7 for the embodiment of Figures 13-17 (and also analogous to extended position of said plungers for the phases of operation shown in Figures 8 and 9 for the embodiment oE Figures 13-17).
It is believed that the construc-tion of modified biaxial CM casting apparatus incorporating modified mold core assemblies 42c and 44d of Figures 25-28, and the mode of opera-tion and functional results thereof according to the present invention will be clear to one skilled in the art from the disclosure herein particularly in light of the detailed disclosure of Figures 25-28 plus Figures 13-17 and Figures 18-19 with reference to Figures 6-12. It is also believed that -the mode of operation of the biaxial CM casting process using the modified apparatus embodiment of Figures 25-28 according to the present invention and functional results thereof also will be fully apparent -to one skilled in the art from the disclosure herein particularly in light of the de-tailed description of Figures 20-25 with reference to Figures 6-12 plus Figures 13-17 and Figures 18-19.

_--r ~2~3~73~

Reference is now made particularly to Figures 29 and 5A
(with reference also to Figure l, and Figures 2-S). Figure 29 shows an embodiment of biaxially cast CM "L-block" made by using the above-described biaxial CM casting apparatus shown in Figures 25-28 and using a biaxial CM casting method disclosed above with reference to said figures. The L-block made by this modification of biaxial CM casting apparatus and method of Figures 25-28 according to the present invention is generally indicated at 30e in Figure 29 and comprises a pair of longitudinally extending face shells 31c and 31 which are interconnected by laterally extending end web 32b, central web 34a, and end web 32c thereby forming two cavities 35c and 35e which extend through CM L-block 30e from the top to the bottom thereof in the direction of the axis of casting as will be apparent from Figure 29 with reference to the other figures mentioned (in the first two sentences of this paragraph). The end web 32b and the central web 34a are each provided with openings 40 which are made by varying the mold cavity during casting and timing such variation of said mold cavity in such a way as to vary the shape of the C2~1 block 30e to provide web openings 40 extending in the direction of a second axis normal to the first axis of casting without a secondary manufacturing operation, as herein disclosed. It is noted that end web 32c is not provided with such an opening 40 (in contrast to biaxially cas-t CM block 30b shown in Figure 5A and biaxially cast CM block 30a shown in Figures 2-5). The biaxially cast CM L-block 30e is also provided with one opening 40d in a portion of the face shell 31c in the region of cavi-ty 35e of block 30e, and said opening 40d extends in the direction of a third axis normal to the axis of casting and also normal to said second axis of openings 40 in webs 32b and 34a. More particularly, said openings 40 in end web 32b and central web 34a are made by varying the mold q3~

7~3~

cavity during cas-ting and timiny such variation by selectively using plungers 66 and 64b of the mold core assembly 42c in extended and re-tracted posi-tions as shown in Figures 25-28 and above explained~ Said opening 40d in the face shell 31c is made by varying the mold cavity during casting and timing such variation of the mold cavity in such a way as to result in variation of the shape of the CM block 30e to provide openings 40d extending normal to the axis of casting and also normal -to said second axis of web openings 40 without any secondary or tertiary manufacturing operation as explained herein. More particularly, said opening 40d in face shell 31c is made by selectively timed extension and retraction of the single axial plunger 66d of mold core assembly 44e of the apparatus disclosed in Figures 25-28 in the operation of said apparatus to perform the biaxial CM
casting method described above with reference -to Figures 25-28.
Referring again now particularly to Figure 29, the resultant L-block 30e may be joined at its end which has opening 40d in face shell 31c to a biaxially cast CM block 30b of configuration such as shown in Figure 5A at the end of a CM block wall section made up of CM blocks like 30b (or 30a) so that the opening 40 in the end web 32b of the adjoining end block 30b of such a CM block wall section will be in communication with opening 40d in face shell 31c of L-block 30e and thus also with cavity 35e of such block 30e.
Hence, piping and/or electrical conduits or the like can be extended through openings 40 in any of such CM blocks 30b into and through face shell opening 40d, cavity 35e and web openings 40 of L-block 3Oe and then extended at the corner of the two adjoining CM block walls into the perpendicular intersecting wall made up of biaxially cast CM blocks 30b having openings 40 in the end and central webs thereof, as ~37~3~

will be apparent to one skillecl in the art :in light oE the showing oE CM blocks 30b in conjunction with CM L-block 30e in Figure 29 and explanation -thereof herein. It a]so will be apparent that the biaxially cast CM T-block 30e used in conjunction with the biaxially cast CM blocks 30b as shown in Figure 29 and herein explained to provide a "corner conection" will also enable the flow of air through the cavities within said intersecting CM block walls (called a "CM block walls corner connection") such as illustrated in Figure 29 and herein described.
Reference is made now to Figures 13-15 for discussion of another modification which is not disclosed as such in the drawings but which will be described with reference to changes made in components shown in said figures. In the embodiment of Figures 13-17, the core bar and mounting assembly generally indicated at 46 and particularly shown in Figures 13-15 includes a conventional type commercially available core bar assembly comprising an elongated core bar 72 with a pair of transversely extending mounting brackets 74 at opposite ends thereof and air couplings 124 and 126 mounted on core bar 72 by welding or any other suitable manner. There are also mounted on core bar 72 air conduit means for connection to a compressed air source and mold core assemblies 42 and 44 for operation thereof to extend and retract the axial plungers 64 and 66. Such air conduit means comprises tubing 144 and 148 plus tubing 128 and related air conduit means connected to and via air blocks 124 and 126 to extend the plungers 64 and 66; and the air conduits for retracting axial plungers 64 and 66 constitutes air tubing 146 and 150 and 1J2 connected to and via air couplings 124 and 126. Also, the low pressure air condui-t for the "air sensor" means to indicate whether or not axial plungers 64 and 66 are fully retracted comprises flexible tubing 178 and air tubing 178a connected to and via air couplings 124 and 126. In lieu of conventional core ~ar 72, a modified core bar (not shown) may be made incorpora-ting (a) the equivalent of air couplings 124 and 126 and air conduit means 144, 124, 128, 148, 126, 128 for extending plungers 64 and 66, plus (b) ~the equivalent of air conduit means 146, 124, 132, 150, 126, 132, plus also (c) the equivalent of low air pressure conduit 178a, 124, 178, 178b, 126 and 178. To accomplish this modified core bar assembly embodiment, at least some of said equivalent air conduit means would be formed within a portion of the modified core bar (similar to 72) which will probably be made in two or more parts welded or similarly secured together. This will make such modification of core bar assembly 46 shown in Figure 13-15 more compact and thereby provide advantages for use of a biaxial CM mold core system like that generally indicated at 41 and thus modified as herein discussed. It will be apparent -to those skilled in the art in light of the disclosure herein with reference to the embodiment of Figures 13-17 that such modification of core bar 72 to incorporate in the core bar air couplings 124 and 126 and related air conduits extending to, between and from air couplings 124 and 126 may be done in various ways according to such modification of the embodiment of Figures 13-15 as herein discussed.
Reference is now made particularly to Figures 30-31 which disclose a "biaxial maintenance module" generally indicated at 182 which is used for cleaning the axial plungers 64 and 66 of mold core assemblies 42 and 44 of the biaxial CM mold core system 41 shown in Figures 13-17 at the end of a particular run or working day or the like~ The maintenance module 182 comprises a base 184 and two side walls 185 and 186 connected at their lower edges to base 184, plus two like end frames 188 connected along their bottom _r 3~

sides to base 184 and along their vertically extending edyes to sides 185 and 186. The maintenance module 182 also includes a center frame 189 connected at -the bo-ttom thereof to base 184 and at the sides thereof to side walls 185 and 186. The two like end frames 188 and center frame 189 may be made in any suitable manner for purposes of mounting below-described cleaning sponges (or equivalent) for cleaning the axial plungers of mold cores 42 and 44; and the particular construction of the biaxial maintenance module 182 shown in Figures 20-22 and below described in detail is exemplary.
Each of like end frames 188 and also middle frame 189 is made up of two vertically extending angle-shaped members 190 interconnected by a pair of horizontally extending members 191 to form three substantially square outer frames comprising part of end frames 188 and center frame 189. Four triangular gussets 192 are secured to members 190 and 191 which form the outer square framework of each of end frames 188 and middle frame 189 as will be apparent from the drawings, particularly Figures 30 and 31. Referring to end frames 188, a cylindrical member 194 of relatively short length is mounted within and secured to gussets 192 of each of end frames 188 in the center thereof in any suitable manner. Similarly, a cylindrical member 195 of relatively short length is mounted within and secured to gussets 192 in the central portion of center frame 189 in any suitable manner. The bottom 184, sides 185 and 186, end frames 188 and center frame 189 may be formed of any suitable material, and such components preferably are made of a strong transparent plastic material selected from one of several commercially available plastic materials which are suitable for the construction and usage of biaxial maintenance module 182. Typically, bottom 184 and sides 185 and 186 would be about 1/2 inch thick and members 191 and 192 could be 1/4" X

~3~7~

1" angles. An annular ring 196 of sponge rubber (or suitable equivalent material) i5 mounted in each of cylinders 194 in end frames 188, as shown particularly ln Figure 32. A
circular piece of sponge rubber (or suitable equivalent material) indicated at 198 is mounted over the outer face portions of cylindrical sponge rubber rings 196 and secured to cylinders 194 on each of end frames 188, as will be apparent particularly from Figures 32 and 31 of the drawings.
Two rings of sponge rubber 196a with a circular piece of sponge rubber 198a disposed therebetween is mounted in the cylindrical member 195 in the central frame member 189 as shown particularly in Figures 32 and 31 of the drawings. In a typical commercial embodiment of the biaxial maintenance module 182, the sponge rings 196 would be about one inch thick and have an outside diameter of about 5-1/2 inches sized to fit within the inside diameter of rings 194 in which said sponge rubber rings 196 are secured by any suitable means. Also, the rings 196 would have an inner diameter slightly smaller than the ou-ter diameter of axial plungers 64 and 66 of the mold core assemblies 42 and 44 which are shown particularly in Figure 13 (and likewise with respect to the plungers of modified mold core assemblies 42b and 44b of the modified embodiments of Figures 18-19). The sponge rings 196a would be approximately one-half inch thick (or slightly more) and would have an outer diameter and inner diameter similar to that of rings 196 as above discussed. The circular sponge members 198 disposed on the outer sides of sponge rubber rings 196 of end frames 188 and the circular sponge member 198a disposed between sponge rubber rings 196a in the middle frame 189 are made of sponge rubber (or equivalent suitable material) about 1/8 inch thick in a typical embodiment of biaxial maintenance module 182.

~`}~7~

At the end oE a run or at the encl of a day, or the like, the biaxial maintenance module 182 is used to clean the cylindrical exteriors of axial plungers 64 and 66 and their respective end portions 65 and 67 oE biaxial CM mold core system 41 shown in Figures 13-17. Referring now to Figures 6-12, the pallet 60 shown in said Figures is mounted on a vertically moving platen (not shown) which is incorporated in CM casting machine 48 and moves up and down wi-th a pallet 60 to carry out various phases of CM biaxial molding process shown in Figures 6-12 and above described. To use the biaxial maintenance module 182, the pla~en is lowered below the mold box 52 of machine 48. The biaxial maintenance module 182 is placed on the thus lowered platen so that when the platen is raised (e.g., as indicated in Figure 6), the mold core assemblies 42 and 44 will respectively enter in-to the two -top open portions of maintenance module 182 with one of said mold core assemblies disposed be-tween center frame 189 and end frame 188 and the other such assembly disposed between center frame 189 and the other end frame 188. The biaxial maintenance module 182 is raised within the mold box 52 so tha-t -the central axis of each of biaxial plungers 64 and 66 of the mold core assemblies 42 and 44 are coincident with the central axes of axially aligned rings 196 and 196a.
The machine 48 is manually operated to cause the plungers 66 of each of the two mold core assemblies 42 to enter the inside of sponge rubber rings 196 with the plunger ends 167 engaging circular end sponges 198 on the frame ends 188.
Plungers 64 of each of said mold core assemblies are simultaneously caused to enter into the centers of middle sponge rubber rings 196a with the ends 65 of axial plungers 64 engaging opposite surfaces of the circular sponge 198a mounted on the central frame member 189. The sponges 196, 196a, 198, and 198a are soaked in water and/or in a silicon-~2~734 containing liquid so as to better clean the surfaces and ends of the axial plungers 6~ and 66 by the above-described biaxial maintenance module. Use of the biaxial maintenance module and cleaning of the axial plungers 6~ and 66 and ends ~65 and 67 thereof as above described is carried out by manual operation of the CM casting machine 48 by the operator.

The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indlcated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
What is claimed and desired to be secured by Letters Patent is:

~63-

Claims

1. A biaxial casting apparatus for making a concrete masonry or CM block including a pair of opposing spaced face shells with at least three spaced webs extending transversely to and interconnecting said face shells and forming at least two cavities bounded by said webs and portions of said face shells, said cavities extending through the CM block in parallel to said webs and face shells, said apparatus adapted to be disposed in a mold of a CM casting machine, said mold including a mold box comprising four substantially vertically disposed side walls disposed in substantially rectangular plan configuration with a first pair of said side walls being longer than a second pair of said side walls, and a movable bottom defining the bottom of a mold cavity during casting, said biaxial casting apparatus comprising:
(a) at least two mold cores substantially vertically disposed in said mold, said mold cores having substantially vertically disposed side walls arranged in substantially rectangular plan configuration, with a wall of each of said mold cores spaced from a wall of an adjacent mold core, and other walls of said mold cores being spaced from side walls of said mold box so as to form a mold cavity in which configuration as the plan of the CM block is to be made;
(b) at least a first one of said mold cores containing means for laterally projecting outwardly from at least one side wall of said mold core during selected phases of a CM casting process using said apparatus so that said means provides a temporary mold core laterally extending into said mold cavity along an axis transverse to said side walls of said core during said selected phases of using said apparatus in casting a CM block so as to form an opening extending through at least one of the adjacent webs of the resultant CM block with; and (c) control means for sequentially (1) extending said laterally projecting means into said mold cavity and (2) retracting said laterally projecting means from said mold cavity following introduction of liquid concrete into said mold cavity in contact with said laterally projecting means, said control means including means for sensing full retraction of the laterally projecting means from the mold cavity to thereby enable prevention of removal of the movable bottom in response to failure of said laterally projecting means to fully retract as sensed by said sensing means.

2. A biaxial casting apparatus for making a CM block as defined in claim 1 wherein:
(a) said at least first one of said mold core contains means for laterally projecting outwardly from opposite side walls of said mold core to provide a pair of temporary mold cores laterally extending into said mold cavity along an axis transverse to said side walls of said core during said selected phases of using said apparatus for casting a CM block so as to form openings extending transversely through at least two adjacent webs of the resultant CM block.

3. A biaxial casting apparatus for making a CM block as defined in claim 1 wherein:
(a) a second of said mold cores contains means for laterally projecting outwardly from opposite side walls of said mold core during said selected phases of a CM casting process using said apparatus with said means projecting laterally outwardly from opposite sides of said first and second mold cores being substantially aligned and together providing at least three coaxial temporary mold cores laterally extending into said mold cavity during said selected phases of using said apparatus in casting of a CM block so as to form openings extending transversely through each of said three spaced webs of the resultant CM block;
(b) the second of said mold cores also containing means for retracting said outwardly projecting means to within the periphery of said second mold core so as to remove the portions of the temporary mold cores formed by said means from said mold cavity during other selected phases of such a CM
casting of process using said apparatus.

4. A biaxial casting apparatus for making a CM block according to claim 1 wherein:
(a) a second of said mold cores contains means for laterally projecting outwardly from one side wall of said second mold core during said selected phases of a CM casting process using said apparatus with said means projecting laterally outward from said first and second mold cores providing at least three coaxial temporary mold cores laterally extending into said mold cavity during said selected phases of such CM casting process so as to form openings extending transversely through each of said three webs of the resultant CM block;
(b) said second mold core also containing means for retracting said outwardly projecting means thereof to within the periphery of said second mold core so as to remove the temporary mold core portion formed by said means of said mold core from said mold cavity during other selected phases of a CM

casting process using said apparatus.

5. A biaxial casting apparatus for making a CM block as defined in claim 2 wherein:
(a) a second of said mold cores contains means for laterally projecting outwardly from at least one of opposite side walls of said mold core to provide at least one temporary mold core laterally extending into said mold cavity along an axis which is transverse to said laterally projecting means of said first one of said mold cores during said selected phases of using said apparatus for casting a CM block so as to form at least one opening extending through at least one face shell of the CM block between a pair of said webs one of which has said web opening therein and another of said does not have any opening therein;
(b) said second mold core also containing means for retracting said outwardly projecting means to within the periphery of said second mold core so as to remove the temporary mold core formed by said means from said mold cavity during other selected phases of such a CM casting process using said apparatus.

6. A biaxial casting apparatus for making of CM blocks as recited in claim 5 wherein, said second mold core contains means for laterally projecting outwardly from two opposite sides of opposite side walls of said mold core to provide a pair of coaxial temporary mold cores extending into said mold cavity along an axis which is transverse to said laterally projecting means of said first one of said mold cores also transverse to the direction of the axis of two said openings during said selected phases of using said apparatus in casting a CM block so as to form a pair of substantially aligned openings one each of said face shells between two webs of the CM block, one of which webs has one of said web openings extending therethrough and the other of said webs not having any such opening extending therethrough.

7. A biaxial casting apparatus for making a CM block according to claims 1 through 6 further comprising: compressed air means for positively causing said laterally projecting means to extend outwardly of the respective mold core to provide a temporary mold core in the mold cavity and also compressed air means for positively retracting said laterally projecting means inwardly to within the periphery of said respective mold core.

8. A biaxial casting apparatus for making a CM block according to claims 1 through 6 wherein said outwardly projecting means provides said opening in said web with an axis extending substantially normal to the web.

9. A biaxial casting apparatus for making a CM block according to claim 6 wherein said means for providing a temporary mold core of said second mold core to make said opening in said one face shell extends substantially normal to the pair of temporary mold cores to said first mold core.

10. A biaxial casting apparatus for making a CM block according to claim 6 wherein said means for providing temporary mold cores to make said pair of openings in said face shells forms said openings in said face shells in a direction substantially normal to the face shells and also substantially normal to the axis of said openings in the webs of the CM
block.

11. A biaxial casting apparatus for making a concrete masonry block including at least one face shell with at least one spacer web extending transversely from said face shell to form at least one space defined by said at least one web and portions of said at least one face shell, said space extending approximately through the height of the block in parallel to said web and face shell, said apparatus adapted to be disposed in the mold of a concrete casting machine with said mold including a mold box comprising substantially vertically disposed walls and a movable bottom, said biaxial casting apparatus comprising:
(a) at least one mold core substantially vertically disposed in said mold, said mold core having substantially vertically disposed side walls with a side wall of said at least one mold core spaced from a wall of said mold box to form a mold cavity therewith;
(b) said at least one mold core containing means for laterally projecting outwardly from a side wall of the mold core during selected phases of casting said block using said apparatus so that said means provides a temporary mold core extending laterally into said mold cavity;
(c) control means for selectively (1) extending said laterally projecting means into said mold cavity and (2) retracting said laterally projecting means from said mold cavity following introduction of liquid concrete into said mold cavity, said control means including means for sensing full retraction of the laterally projecting means from the mold cavity to thereby enable prevention of removal of the movable bottom in response to failure of said laterally projecting means to fully retract as sensed by said sensing means.

12. A biaxial casting apparatus for making a concrete masonry or CM block including at least one face shell, said apparatus adapted to be disposed in the mold of a CM casting machine with said mold including a mold box comprising side wall means and a movable bottom, said biaxial casting apparatus comprising at least one mold core means forming a mold cavity with said side wall means, said mold core means including means for laterally projecting outwardly from the side wall means of the mold core means into the mold cavity along an axis transverse to the side wall means of said mold core means during selected phases of using said apparatus and casting a concrete masonry block; and control means for selectively extending and retracting said laterally projecting means, said control means including means for sensing full retraction of the laterally projecting means from the mold cavity to thereby enable prevention of removal of the movable bottom in response to failure of said laterally projecting means to fully retract as sensed by said sensing means.

13. A concrete mold core assembly for making a concrete masonry block, said assembly comprising a mold box including side wall means for forming at least part of a mold cavity; at least one mold core having substantially vertically disposed wall means establishing with said side wall means a mold cavity open at top and bottom ends thereof, an axis extending vertically between the top and bottom ends being an axis of casting; said at least one mold core means containing means for laterally projecting outwardly from the mold core into said vertically disposed wall means of the mold cavity along an axis transverse to the casting axis; a materials feed tray movable into an overhead position above the mold box to feed liquid concrete into the mold cavity; a pallet movable into position adjacent the bottom end of the mold cavity to establish a mold cavity bottom to retain said liquid concrete in the mold cavity to form the block; a compression stripper shoe movable in the direction of the axis of casting to strip a cast concrete masonry block from the mold cavity in coordination with said pallet being moved to a spaced location away from the mold cavity bottom end; and control means for selectively extending said laterally projecting means into said mold cavity, said control means being operable to retract said laterally projecting means from said mold cavity following introduction of liquid concrete into said mold cavity, retraction of said laterally projecting means from said mold cavity occurring prior to removal of said pallet from the mold cavity bottom, said control means including means for sensing full retraction of the laterally projecting means from the mold cavity to thereby enable prevention of removal of the pallet in response to failure of said laterally projecting means to fully retract as sensed by said sensing means.

14. The concrete mold core assembly of claim 13, said control means further comprising air supply means for pneumatically extending and retracting said laterally projecting means.

15. The concrete mold core assembly of claim 13, wherein said laterally projecting means includes at least one plunger extendable into the mold cavity through an opening in the vertically disposed wall means.

16. The mold core assembly of claim 15, said laterally projecting means further including a pair of said plungers movable into the mold cavity along a common axis.

17. The mold core assembly of claim 16, wherein ends of said plungers, in their extended mode, to abut adjacent side walls of the mold box side wall means.

18. The mold core assembly of claim 13, wherein said mold core includes an assembly sleeve, a manifold member supported within the assembly sleeve, said manifold member having at least one stationary piston member at one end thereof, said laterally projecting means being slidably carried on said at least one end of the manifold member carrying said stationary piston member, the stationary piston member sealingly and slidably engaging an internal hollow area of the laterally projecting means.

19. The mold core assembly of claim 18, wherein said laterally projecting means is a plunger, and further including at least one sweeper gasket disposed between an outer periphery of the plunger and an inner periphery of the manifold member opposing the outer periphery to wipe concrete material from an exterior surface of the plunger during retraction.

20. The mold core assembly of claim 19, wherein said manifold member includes a first set of passageways connected to air supply means for pneumatically operating the plunger to supply air into a portion of the hollow area of the plunger defined by one side of the piston to retract the plunger from its extended mode, and a second set of air supplied passages supplying air to the other side of the piston to extend the plunger in its extension mode.

21. The mold core assembly of claim 20, further comprising means for venting air from within the manifold through the plunger to break the negative pressure and vacuum effect around the periphery of the plunger within the mold cavity as the plunger starts to retract from its extended mode.

22. The mold core assembly of claim 21, further comprising means for relieving air pressure from between the plunger and manifold as the plunger starts to retract from its extended mode.

23. The mold core assembly of claim 22, wherein said control means includes air pressure supplied nipple means positioned to be blocked of by an exterior periphery of the plunger in its fully retracted mode, said sensing means communicating with the nipple means to detect a minimum back pressure applied thereto by blockage of the nipple means by the plunger to determine whether the plunger has failed to retract if the sensor means senses a back pressure below the minimum back pressure.

24. The mold core assembly of claim 23, further including means for simultaneously retracting said plunger as the compression/stripper shoe is raised to above the feed tray.

25. The mold core assembly of claim 23, wherein said sensing means includes a pressure gauge indicating the back pressure to an operator to enable manual intervention if the indicated pressure is less than the minimum back pressure.

26. The mold core assembly of claim 23, further including a plurality of substantially identical mold cores each containing at least two plungers movable along a common axis during their extension and retraction modes.

27. The mold core assembly of claim 26, wherein the pair of plungers of one mold core assembly lie along a common axis which is perpendicular to the common axis of the pair of plungers in an adjacent mold core to provide a tri-axially cast block.

28. A biaxial casting method for making a concrete masonry or CM block including a pair of opposing spaced face shells with at least three spaced webs extending transversely to and interconnecting said face shells and forming at least two cavities which are boundaried by said webs and portions of said face shells and extend through said CM block in the direction of an axis of casting of such block, said method using an apparatus adapted to be disposed in the mold of a CM
casting machine with said mold including a mold box comprising four substantially vertically disposed side walls disposed in substantially rectangular plan configuration with a first pair of said side walls being longer than the second pair of said side walls, and said apparatus comprising: at least two mold cores substantially vertically disposed in said mold, said mold cores having substantially vertically disposed side walls arranged in substantially rectangular plan configuration, with a wall of each of said mold cores spaced from a wall of an adjacent mold core and other walls of said mold cores being spaced from side walls of said mold box so as to form a mold cavity which has a plan configuration like the plan of said CM
block to be made, with the vertical axis of said mold cores extending in the direction of said axis of casting of said CM
block to be made, at least one of said mold cores containing means for laterally projecting from within the periphery of said mold core to outwardly of at least one side of said mold core in like longitudinal direction as said first longer mold side walls to provide a temporary mold core laterally extending into said mold cavity in a direction transverse to said axis of casting; compressor/stripper means vertically movable with respect to said mold box and mold cores, pallet means vertically and laterally movable with respect to the bottom of said mold box, and CM material feed means laterally movable to above said mold box and away therefrom said biaxial casting method for making said CM block comprising:
(a) disposing a pallet with respect to said mold box to provide a mold bottom; extending said laterally projecting means from at least one of said mold cores into said mold cavity to provide said temporary mold core laterally extending into said mold cavity along an axis transverse to said axis of casting; feeding CM mix into said mold cavity from said feeder means; and vertically lowering said compressor/stripper means and compressing said CM mix in said mold cavity to form a CM
block having an opening extending through at least one of said webs of said CM block; and (b) retracting said laterally projecting means to within said periphery of said mold core containing same to remove said temporary mold core from said mold cavity; sensing with a sensing means whether said laterally projecting means has fully retracted from said mold cavity; moving said compressor stripper means and said pallet downward to strip from said mold box said CM block disposed on said pallet when said sensing means has sensed that said laterally projecting means has fully retracted from said mold cavity; transferring said CM block and pallet laterally away from below said mold box; placing another pallet below said mold box and vertically raising said pallet to said mold box to provide a mold bottom;
and vertically raising said compressor/stripper means from said mold box and disposing it out of the path of said laterally movable CM material feed means.

29. A biaxial casting method for making a concrete masonry or CM block including a pair of opposing spaced face shells with at least three spaced webs extending transversely to and interconnecting said face shells and forming at least two cavities which are boundaried by said webs and portions of said face shells and extend through said CM block in the direction of the axis of casting of said CM block, said method comprising:
(a) providing a CM casting machine with a mold including a mold box comprising four substantially vertically disposed side walls disposed in substantially rectangular plan configuration with a first pair of said side walls being longer than the second pair of said side walls;
(b) providing at least two mold cores substantially vertically disposed in said mold with said mold cores having substantially vertically disposed side walls arranged in substantially rectangular plan configuration, with a wall of each of said mold cores spaced from each other and other walls of said mold cores being spaced from side walls of said mold box so as to form a mold cavity which has a plan configuration similar to the plan configuration of said CM block to be made, with the vertical axis of said mold cores extending in the direction of said axis of casting of said CM block to be made, at least one of said mold cores containing means for laterally projecting from within the periphery of the mold core to outwardly of at least one side of said mold core in direction of a second axis which extends in like longitudinal direction as said first longer mold side walls and substantially normal to said axis of casting to provide a temporary mold core laterally extendable into said mold cavity in said direction of said second axis;
(c) providing a mold bottom for said mold box;
(d) extending said laterally projecting means outwardly from at least one of the mold cores into the mold cavity to provide a temporary mold core laterally extending into the mold cavity along said second axis;
(e) feeding CM mix into the mold cavity;
(f) compressing said CM mix in said mold cavity to form said CM block having an opening extending through at least one of said webs of said CM block;
(g) retracting said laterally projecting means to within said periphery of said mold core containing same to remove said temporary mold core from said mold cavity and sensing with a sensing means whether said laterally projecting means has fully retracted from said mold cavity;
(h) removing said mold bottom when said sensing means has sensed that laterally projecting means has fully retracted from said mold cavity; and (i) removing said cast CM block from said mold box.

30. A biaxial casting method for making a concrete masonry block including a pair of opposing spaced face shells with at least three spaced webs extending transversely to interconnect said shells and form at least two cavities bounded by said webs and portions of said face shells, said cavities extending through the block in said direction of the axis of casting of said block, said method comprising the steps of:
(a) providing a CM casting machine with a mold including a mold box comprising four substantially vertically disposed side walls disposed in substantially rectangular plan configuration with a first pair of said side walls being longer than the second pair of said walls and providing at least two mold cores substantially vertically disposed in said mold;
(b) providing a mold bottom for said mold box;
(c) extending a laterally projecting means outwardly from at least one of the mold cores into said mold cavity to provide a temporary mold core laterally extending into said mold cavity along an axis generally perpendicular to said casting axis;
(d) feeding concrete mix into said mold cavity;
(e) compressing said mix in said mold cavity to form said block having an opening extending through at least one of said webs of said block;
(f) retracting said laterally projecting means from said concrete mix in said mold cavity to within the periphery of said mold core containing same to remove said temporary mold core from said mold cavity and sensing with a sensing means, whether said laterally projecting means has fully retracted from said mold cavity;
(g) removing said mold bottom when said sensing means has sensed that said laterally projecting means has fully retracted from said mold cavity; and (h) removing said cast block from said mold box.

31. A biaxial casting method for making a concrete masonry block including at least one face shell with apparatus adapted to he disposed in a mold of a CM casting machine with said mold including a mold box comprising side wall means, said casting apparatus comprising at least one mold core means forming a mold cavity with said side wall means, said mold core means including means for laterally projecting outwardly from said mold core means into said mold cavity, comprising the steps of:
(a) providing a mold bottom for said casting apparatus;
(b) extending said laterally projecting means from said mold core means into said mold cavity to provide a temporary mold core extending into said mold cavity along a first axis;
(c) feeding concrete mix into said mold cavity along a second axis angularly offset from said first axis;
(d) compressing said mix into the mold cavity to form said concrete masonry block;
(e) retracting said laterally projecting means to within said periphery of the mold core means to remove said laterally projecting means from said mold cavity;
(f) sensing with a sensing means whether said laterally projecting means has completely retracted from said mold cavity;
(g) removing said mold bottom only when said sensing means has sensed that the laterally projecting means has completely retracted in accordance with step (f), and (h) removing said cast concrete block from said mold box.

32. The biaxial casting method of claim 31, wherein said laterally projecting means is pneumatically extended and retracted.

33. The biaxial casting method of claim 32, wherein said laterally projecting means is extended into said mold cavity through an opening in a side wall of said mold core means.

34. The biaxial casting method of claim 33, comprising the further step of wiping an outer periphery of said laterally projecting means as it retracts into said mold core means utilizing sweeper gaskets disposed between said outer periphery of said laterally projecting means and within said mold core means.

35. The biaxial casting method of claim 33, wherein air is supplied into a hollow portion of said laterally projecting means against one side of a stationary piston head within said laterally projecting means to extend said laterally projecting means, wherein air is sequentially supplied to within said laterally projecting means against an opposite side of said piston to retract said laterally projecting means.

36. The biaxial casting method of claim 35, comprising the further step of venting air from within said mold core means through said laterally projecting means to break a negative pressure and vacuum around said outer periphery of said laterally projecting means within said mold cavity filled with CM material as said laterally projecting means starts to retract from its extended mode.

37. The biaxial casting method of claim 36, comprising the further step of relieving air pressure between said laterally projecting means and said mold core means as said laterally projecting means starts to retract from said extended mode.

38. The biaxial casting method of claim 31, comprising the further step of supplying air under pressure to a nipple means positioned within said mold core means to be blocked off by said outer periphery of said laterally projecting means in its fully retracted mode, and wherein said sensing step of subparagraph (f) includes the further step of detecting the occurrence of a predetermined minimum back pressure applied to said nipple means by blockage thereof with said outer periphery of said laterally projecting means to determine full retraction, thereof, or incomplete retraction thereof when said detected pressure is below said predetermined minimum back pressure.

39. The biaxial casting method of claim 37, comprising the further step of supplying air under pressure to a nipple means positioned within said mold core means to be blocked off by said outer periphery of said laterally projecting means in its fully retracted mode, and wherein the sensing step of subparagraph (f) includes the further step of detecting the occurrence of a predetermined minimum back pressure applied to said nipple means by blockage thereof with said outer periphery of said laterally projecting means to determine full retraction for incomplete retraction thereof when said detected pressure is below the predetermined minimum back pressure.

40. The biaxial casting method of claim 38, wherein said back pressure is determined with a pressure gauge indicating to an operator when said back pressure is greater than or equal to said predetermined minimum back pressure to enable manual intervention by said operator to prevent removal of said mold bottom when said indicated pressure is less than said predetermined minimum back pressure.

41. The biaxial casting method of claim 31, wherein said mold includes a pair of substantially identical said mold core means with said laterally projecting means being respectively extendable and retractable along two different angularly offset first axes, and comprising the further step of extending said respective laterally projecting means along their respective first axis to provide a triaxially cast block.
41. The biaxial casting method of claim 31, wherein said mold core means includes at least a pair of said mold core means each having said laterally projecting means to form a concrete masonry block including a pair of opposing spaced face shells with at least three spaced webs extending transversely to interconnect said shells and form at least two cavities bounded by said webs and portions of said face shells.
43. A biaxial casting method for forming a concrete masonry block including walls enclosing at least one cavity extending through the block in a first direction and at least one opening or indentation extending through at least one of the walls in a second direction transverse to the first direction; apparatus used in said method adapted to be disposed in a mold of a concrete masonry casting machine, the mold including a mold box having side walls and an open bottom; the apparatus comprising at least one mold core having walls enclosing a cavity, the walls of the mold core disposable in the mold box and including at least one laterally projecting means movable between a first position extending outwardly from the mold core and into the mold cavity for receiving the concrete mix, and a second position retracted into the periphery of the mold core; the method in using said apparatus comprising the steps of:
providing a mold box base which is displaceable from the bottom of the mold box;
disposing at least one mold core into the mold box and extending the laterally projecting means to provide a temporary mold core means;
feeding concrete mix into the mold cavity;
compressing the mix in the mold cavity to form a concrete masonry block;
retracting said laterally projecting means from said mold cavity;
removing said mold box base from the bottom of the mold box; and removing said cast concrete masonry block through the bottom of the mold box.
44. A method as claimed in claim 43 wherein the mold box base is removed by exerting a downward force on the cast concrete masonry block to displace it downwardly with the mold box base and away from the mold box.

45. A biaxial casting method as claimed in claim 43 wherein the mold box base is a pallet.
46. A biaxial casting method as claimed in any one of claims 43 to 45 wherein, in the apparatus, both first and second mold cores comprise two opposed laterally projecting means which are all extended, in accordance with the claimed method, in like longitudinal direction to form three corresponding openings or indentations in the webs, the adjacent laterally projecting means of the first and second mold cores abutting one another when extended.
47. A biaxial casting method as claimed in claim 46 wherein, in the apparatus, the first mold core has two laterally projecting means which are extended in the longitudinal direction of the concrete masonry block for forming two openings or indentations in adjacent webs, and the second mold core has at least one laterally projecting means extended across the concrete masonry block for forming an opening or indentations in a face shell.
48. A biaxial casting method as claimed in claim 47 wherein, in the apparatus, the second mold core has two laterally projecting means in opposed walls, which are extended across the concrete masonry block for forming corresponding openings or indentations in the opposed face shells.
49. A biaxial casting method as claimed in any one of claims 43 to 45 wherein the apparatus further comprises compressed air means for positively causing said laterally projecting means to extend outwardly of its associated mold core to provide temporary mold cores in the mold cavity and also compressed air means for positively retracting inwardly each of said laterally projecting means to within the periphery of its mold core.

50. A biaxial casting method as claimed in any one of claims 43 to 45 further including web or said face shell openings or indentations to extend substantially normal to the axis of casting.

51. A biaxial casting method as claimed in any one of claims 43 to 45 wherein the laterally projecting means is a plunger.

52. A biaxial casting apparatus for making a concrete masonry or CM block including at least one face shell, said apparatus adapted to be disposed in the mold of a CM casting machine with said mold including a mold box comprising side wall means and a movable bottom, said biaxial casting apparatus comprising at least one mold core means forming a mold cavity with said side wall means, said mold core means including means for laterally projecting outwardly from the side wall means of the mold core means into the mold cavity along an axis transverse to the side wall means of said mold core means during selecting phases of using said apparatus and casting a concrete masonry block; and control means for selectively extending and retracting said laterally projecting means.
53. A biaxial casting apparatus for making a concrete masonry or CM block including at least one face shell, said apparatus adapted to be disposed in the mold of a CM casting machine with said mold including a mold box comprising side wall means and a movable bottom, said biaxial casting apparatus comprising at least one mold core means forming a mold cavity with said side wall means, and means for laterally projecting outwardly into the mold cavity along an axis transverse to the side wall means of said mold core means during selected phases of using said apparatus to cast a concrete masonry block; and control means for selectively extending and retracting said laterally projecting means.

54. The apparatus of claim 52, wherein said control means further includes means for sensing full retraction of laterally projecting means from the mold cavity to thereby enable prevention of removal of the mold bottom in response to failure of said laterally projecting means to fully retract as sensed by said sensing means.