Nested masonry block manufacturing system and method

Abstract

A masonry block set is disclosed that includes a first block having a first rectangular body and a first rectangular protrusion from a front face of the first rectangular body. A second block has a second rectangular body and a second rectangular protrusion from a front face of the second rectangular body. The first block and the second block can be combined to form a nested block pair where a front face of the first rectangular protrusion abuts the front face of the second rectangular body and a front face of the second rectangular protrusion abuts the front face of the first rectangular body.

What is claimed is: 
     
         1 . A masonry block set comprising:
 a first block having a first rectangular body and a first rectangular protrusion from a front face of the first rectangular body;   a second block having a second rectangular body and a second rectangular protrusion from a front face of the second rectangular body; and   wherein the first block and the second block can be combined to form a nested block pair where a front face of the first rectangular protrusion abuts the front face of the second rectangular body and a front face of the second rectangular protrusion abuts the front face of the first rectangular body.   
     
     
         2 . The masonry block set of  claim 1  wherein the first rectangular protrusion comprises a split surface. 
     
     
         3 . The masonry block set of  claim 1  wherein the front face of the first rectangular protrusion comprises a split surface. 
     
     
         4 . The masonry block set of  claim 1  wherein the nested block pair comprises a split extending through the first rectangular protrusion and the second rectangular protrusion. 
     
     
         5 . The masonry block set of  claim 1  wherein the first rectangular body and the second rectangular body have a first predetermined length, the first rectangular protrusion has a second predetermined length, the second rectangular protrusion has a third predetermined length, and the first predetermined length equals a sum of the second predetermined length and the third predetermined length. 
     
     
         6 . The masonry block set of  claim 1  wherein the first rectangular body and the second rectangular body have a first predetermined length, the first rectangular protrusion has a second predetermined length, the second rectangular protrusion has a third predetermined length, and the first predetermined length is greater than a sum of the second predetermined length and the third predetermined length. 
     
     
         7 . The masonry block set of  claim 1  wherein the first rectangular body and the second rectangular body have a first predetermined length. 
     
     
         8 . The masonry block set of  claim 7 , wherein the first rectangular protrusion has a second predetermined length. 
     
     
         9 . The masonry block set of  claim 8 , wherein the second rectangular protrusion has a third predetermined length. 
     
     
         10 . The masonry block set of  claim 9 , wherein the first predetermined length is greater than a sum of the second predetermined length and the third predetermined length. 
     
     
         11 . A method of manufacturing a masonry block set comprising:
 forming a first block having a first rectangular body and a first rectangular protrusion from a front face of the first rectangular body;   forming a second block having a second rectangular body and a second rectangular protrusion from a front face of the second rectangular body; and   combining the first block and the second block to form a nested block pair where a front face of the first rectangular protrusion abuts the front face of the second rectangular body and a front face of the second rectangular protrusion abuts the front face of the first rectangular body.   
     
     
         12 . The method  claim 11  further comprising splitting the first block. 
     
     
         13 . The method of  claim 11  further comprising splitting the second block. 
     
     
         14 . The method of  claim 11  further comprising splitting the first rectangular protrusion and the second rectangular protrusion in a single splitting operation. 
     
     
         15 . The method of  claim 11  wherein the first rectangular body and the second rectangular body have a first predetermined length, the first rectangular protrusion has a second predetermined length, the second rectangular protrusion has a third predetermined length, and the first predetermined length equals a sum of the second predetermined length and the third predetermined length. 
     
     
         16 . The method  claim 11  wherein the first rectangular body and the second rectangular body have a first predetermined length, the first rectangular protrusion has a second predetermined length, the second rectangular protrusion has a third predetermined length, and the first predetermined length is greater than a sum of the second predetermined length and the third predetermined length. 
     
     
         17 . The method of  claim 11  wherein the first rectangular body and the second rectangular body have a first predetermined length. 
     
     
         18 . The method of  claim 17 , wherein the first rectangular protrusion has a second predetermined length. 
     
     
         19 . The method of  claim 18 , wherein the second rectangular protrusion has a third predetermined length. 
     
     
         20 . The method of  claim 19 , wherein the first predetermined length is greater than a sum of the second predetermined length and the third predetermined length.