Building and training block and process for making

Abstract

A process for making blocks with simulated masonry faces which involves forming individual building or training block shapes and applying a decorative arrangement of mortar lines on each block surface. The decorated surfaces are etched according to the decorative line arrangement and thereafter smoothed and finished to form finished blocks bearing simulated masonry faces. The product made by the process is also included as part of the invention.

1 . A process of making building and training blocks having simulated masonry faces comprising the steps of: forming a block segment having one or more surfaces from a larger segment of material; applying a decorative arrangement of lines on the one or more block surfaces; etching out the decorative arrangement of lines to create simulated mortar lines on the one or more block surfaces; smoothing the one or more block surfaces without removing the etched decorative arrangement of lines; and finishing the one or more block surfaces to form a finished block segment of simulated masonry faces on the one or more block surfaces.  
   
   
       2 . The process as claimed in  claim 1  wherein the simulated mortar lines displayed on all block surfaces extend consistently to adjacent block surfaces.  
   
   
       3 . The process as claimed in  claim 1  wherein the block material is wood.  
   
   
       4 . The process as claimed in  claim 2  wherein the block material is wood.  
   
   
       5 . The process as claimed in  claim 1  further comprising the steps of: forming additional block pieces of varying sizes having one or more surfaces; applying decorative arrangements of lines to create simulated mortar lines on the one or more surfaces; smoothing the one or more block surfaces without removing the etched decorative arrangements of lines; and finishing the one or more block surfaces to form a finished block with simulated masonry faces on the one or more block surfaces.  
   
   
       6 . The process as claimed in  claim 5  wherein the simulated mortar lines displayed on all block surfaces extend consistently to adjacent block surfaces.  
   
   
       7 . The process as claimed in  claim 5  wherein the block material is wood.  
   
   
       8 . The process as claimed in  claim 6  wherein the block material is wood.  
   
   
       9 . A block made by the process set forth in  claim 1 .  
   
   
       10 . A block made by the process set forth in  claim 5 .  
   
   
       11 . The process as claimed in  claim 1  wherein the block material is plastic.  
   
   
       12 . The process as claimed in  claim 5  wherein the block material is plastic.  
   
   
       13 . A process of making building and training blocks having simulated masonry faces comprising the steps of: forming a unit block having one or more surfaces from a larger segment of material; applying a decorative arrangement of lines on the one or more unit block surfaces; etching out the decorative arrangement of lines to create simulated mortar lines on the one or more unit block surfaces; smoothing the one or more unit block surfaces without removing the etched decorative arrangement of lines; and finishing the one or more unit block surfaces to form a finished unit block of simulated masonry faces on the one or more unit block surfaces.  
   
   
       14 . The process as claimed in  claim 13  wherein the simulated mortar lines displayed on all unit block surfaces extend consistently to adjacent unit block surfaces.  
   
   
       15 . The process as claimed in  claim 13  wherein the unit block material is wood.  
   
   
       16 . The process as claimed in  claim 13  wherein the unit block material is wood.  
   
   
       17 . The process as claimed in  claim 13  further comprising the steps of: forming additional unit block pieces of varying sizes having one or more surfaces; applying decorative arrangements of lines to create simulated mortar lines on the one or more surfaces; smoothing the one or more unit block surfaces without removing the etched decorative arrangements of lines; and finishing the one or more unit block surfaces to form finished unit blocks with simulated masonry faces on the one or more unit block surfaces.  
   
   
       18 . The process as claimed in  claim 17  wherein the simulated mortar lines displayed on all unit block surfaces extend consistently to adjacent unit block surfaces.  
   
   
       19 . The process as claimed in  claim 17  wherein the unit block material is plastic.  
   
   
       20 . A unit block made by the process set forth in  claim 13 .  
   
   
       21 . A unit block made by the process set forth in  claim 13 .  
   
   
       22 . The process as claimed in  claim 18  wherein the unit block material is plastic.