Methods and apparatuses relating to block receptor configurations and block assembly processes

Abstract

The present invention approaches the filling efficiency problem from the perspective of the block receptor sites independent of any modification to existing manufacturing equipment or general block geometry. The present invention teaches the use of receptor site openings consisting of various shapes to increase the filling efficiency by improving the ease with which a right-side-up block can deposit into a receptor site opening while preventing improperly oriented blocks from completely entering the block receptor site and enhancing the ease with which incorrectly seated and upside down blocks can be removed from the receptor site.

1 . A receptor site for a block comprising: 
 an opening with varying depths formed from a substrate with a block receptor site of maximum depth in one part of the opening and an exit ramp in another part immediately adjacent to the block receptor site that rises and extends from one edge of the block receptor site to the opposite edge of the opening.    
     
     
         2 . The receptor site of  claim 1  wherein the block receptor site has at least one sidewall which angles down and toward the middle of the block receptor site and a sidewall bordering the block receptor site and the exit ramp that is shorter than other sidewalls of the block receptor site.  
     
     
         3 . The receptor site of  claim 2  wherein the exit ramp is recessed sufficiently deep, with a maximum depth of the exit ramp no more than 50% of maximum depth of the receptor site, such that a top surface of an inverted block cannot contact the block receptor site sidewall from which the exit ramp extends.  
     
     
         4 . The receptor site of  claim 3  wherein the exit ramp rises gradually in at least two sections with different rising angles from the edge bordering the block receptor site to a top surface of the opposite edge of the opening.  
     
     
         5 . The receptor site of  claim 3  wherein the exit ramp rises gradually in one continuous slope or curve from the edge bordering the block receptor site to a top surface of the substrate at the opposite edge of the opening.  
     
     
         6 . A method for improving filling process of mating blocks to a substrate comprising: 
 moving the substrate with an opening containing a block receptor site and an exit ramp in one direction and traveling up an incline;    orienting the exit ramp on the downhill side of the substrate relative to the block receptor site;    filling the block receptor sites with the blocks as the substrate is moving;    flowing any blocks improperly positioned in the block receptor site over the exit ramp by way of gravity while leaving properly positioned blocks in the block receptor site.    
     
     
         7 . The method of  claim 6  wherein the opening has varying depths with the block receptor site of maximum depth in one part of the opening and the exit ramp, which is a sliding region, adjacent to the block receptor site rising and extending from one side of the block receptor site to a substrate surface at opposite edge of the opening.  
     
     
         8 . The method of  claim 7  wherein the block receptor site has at least one sidewall that angles down and toward the middle of the block receptor site and a sidewall bordering the block receptor site and the exit ramp is shorter than other sidewalls of the block receptor site.  
     
     
         9 . The method of  claim 8  wherein the exit ramp is recessed sufficiently deep, with a maximum depth of the exit ramp is no more than 50% of maximum depth of the receptor site, such that a top surface of an inverted block cannot contact the block receptor site sidewall from which the exit ramp extends.  
     
     
         10 . The method of  claim 9  wherein the exit ramp rises gradually in at least two sections with different rising angles from the edge bordering the block receptor site to a top surface of the opposite edge of the opening.  
     
     
         11 . The method of  claim 9  wherein the exit ramp rises gradually in one continuous slope or curve from the edge bordering the block receptor site to a top surface of the substrate at the opposite edge of the opening.  
     
     
         12 . A receptor site for a block comprising: 
 an opening with different depths formed from a substrate with at least two recesses of different depths locate adjacently side by side in parallel, where a deeper recess is both longer and wider than a shallower recess and forms a block receptor site at a region not bordering the shallower recess.    
     
     
         13 . The receptor site of  claim 12  wherein all sidewalls of the deeper recess are sloped down and in toward middle of the deeper recess with one sidewall between the deeper recess and the shallower recess shorter than all other sidewalls of the deeper recess.  
     
     
         14 . The receptor site of  claim 13  wherein both the shallower recess and the deeper recess each has a different but uniform width along lengthwise of the opening.  
     
     
         15 . The receptor site of  claim 14  wherein the shallower recess has a width approximately ranging from at least one-tenth shortest top edge of the block to just shorter than a longest top edge of the block.  
     
     
         16 . The receptor site of  claim 14  wherein the deeper recess and the block receptor site both share a common width that approximately ranges between nearly shortest top edge of the block and nearly two times shortest top edge of the block.  
     
     
         17 . The receptor site of  claim 14  wherein the shallower recess has a different but constant depth compared to the same depth shared by the deeper recess and the block receptor site.  
     
     
         18 . A method for improving filling process of mating blocks to a substrate comprising: 
 depositing the blocks using a filling process into the substrate with an opening containing at least two recesses of different depths located adjacently side by side in parallel, where a deeper recess forming a block receptor site is both longer and wider than a shallower recess;    removing excess or improperly positioned blocks from the substrate surface and the block receptor site by a device mechanism;    sliding remaining blocks lengthwise to a far side of the block receptor site not bordering the shallower recess;    removing the remaining blocks from the block receptor site by a device mechanism leaving one block properly positioned in the block receptor site.    
     
     
         19 . The method of  claim 18  wherein all sidewalls of the deeper recess are sloped down and in toward middle of the deeper recess with one sidewall between the deeper recess and the shallower recess shorter than other sidewalls of the deeper recess.  
     
     
         20 . The method of  claim 19  wherein both the shallower recess and the deeper recess each has a different but uniform width along lengthwise of the opening.  
     
     
         21 . The method of  claim 20  wherein the shallower recess has a width ranging from one-tenth shortest top edge of the block to just shorter than a longest top edge of the block.  
     
     
         22 . The method of  claim 20  wherein the deeper recess has a width that ranges approximately between nearly shortest top edge of the block and two times shortest top edge of the block.  
     
     
         23 . The method of  claim 20  wherein both the shallower recess and the deeper recess each has a different but constant depth.  
     
     
         24 . The method of  claim 20  wherein the deeper recess has a depth allowing the block to be flush or within a distance of about 0% to about 30% thickness of the block from a top surface of the substrate.  
     
     
         25 . The method of  claim 18  wherein the device mechanism comprises at least one of a clearing blade or wiper, a brush, a static or rotating foam roller and any other mechanical clearing device.