U.S. patent application number 10/934661 was filed with the patent office on 2005-05-19 for interlocking masonry wall block.
This patent application is currently assigned to Bend Industries, Inc.. Invention is credited to Whitson, Robert L..
Application Number | 20050102949 10/934661 |
Document ID | / |
Family ID | 34576581 |
Filed Date | 2005-05-19 |
United States Patent
Application |
20050102949 |
Kind Code |
A1 |
Whitson, Robert L. |
May 19, 2005 |
Interlocking masonry wall block
Abstract
Single masonry units mate with like units to build straight
walls, inside curves, outside curves and most any angle corners and
maintains finish on all exposed surfaces. The interlocking
fastening system provides simple construction and automatic wall
alignment.
Inventors: |
Whitson, Robert L.; (West
Bend, WI) |
Correspondence
Address: |
RYAN KROMHOLZ & MANION, S.C.
POST OFFICE BOX 26618
MILWAUKEE
WI
53226
US
|
Assignee: |
Bend Industries, Inc.
|
Family ID: |
34576581 |
Appl. No.: |
10/934661 |
Filed: |
September 3, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60500492 |
Sep 5, 2003 |
|
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Current U.S.
Class: |
52/596 |
Current CPC
Class: |
E04B 2002/0265 20130101;
E04C 1/395 20130101; E04B 2002/0215 20130101; E04B 2002/0263
20130101; E04B 2002/026 20130101 |
Class at
Publication: |
052/596 |
International
Class: |
E04F 017/00 |
Claims
I/We claim:
1. A masonry wall block for forming a retaining wall comprising: a
body having a front wall, a rear wall, and first and second side
walls, each of the walls having inside and outside surfaces and
upper and lower surfaces, the inside surfaces of the walls forming
an open core having a width, the upper surfaces of the walls
forming an upper surface of the body, and the lower surfaces of the
walls forming a lower surface of the body, and first and second
projections extending from the lower surface of the body, the first
projection extending from the lower surface of the first side wall
and the second projection extending from the lower surface of the
second side wall, the core having a width less than 1.25 times the
width of the projection, the first and second projections being
adapted for placement within the cavity of an underlying block in
the retaining wall.
2. A masonry wall block as in claim 1, wherein the outside surface
of the front wall is of a linear configuration.
3. A masonry wall block as in claim 1, wherein the outside surface
of the rear wall is of a linear configuration.
4. A masonry wall block as in claim 1, wherein core is of a
non-tapered width.
5. A masonry wall block as in claim 1, wherein the core is offset
between the front and rear wall outer surfaces.
6. A masonry wall block as in claim 1, wherein core is centered
between the front and rear wall outer surfaces.
7. A masonry wall block as in claim 1, wherein the first and second
projections are offset between the front and rear wall inside
surfaces.
8. A masonry wall block as in claim 1, wherein the first and second
projections are spaced equidistant between the front and rear wall
inside surfaces.
9. A masonry wall block for forming a retaining wall comprising: a
body having a front wall, a rear wall, and first and second side
walls, each of the walls having inside and outside surfaces and
upper and lower surfaces, the inside surfaces of the walls forming
an open core, the upper surfaces of the walls forming an upper
surface of the body, and the lower surfaces of the walls forming a
lower surface of the body, and first and second projections
extending from the lower surface of the body, the first projection
extending from the lower surface of the first side wall and the
second projection extending from the lower surface of the second
side wall, the first and second projections being adapted for
placement within the cavity of an underlying block in the retaining
wall, at least one of the first and second side walls including a
score line between the cavity and the respective first or second
projection, the score line extending from the front wall outer
surface to the rear wall outer surface.
10. A masonry wall block as in claim 9, wherein the core is spaced
equidistant between the front and rear wall outer surfaces.
11. A masonry wall block as in claim 9, wherein the core is offset
between the front and rear wall outer surfaces.
12. A masonry wall block as in claim 1, wherein the first and
second projections are offset between the front and rear wall
inside surfaces.
13. A masonry wall block as in claim 1, wherein the first and
second projections are spaced equidistant between the front and
rear wall inside surfaces.
14. A masonry wall block for forming a retaining wall comprising: a
body having a front wall, a rear wall, and first and second side
walls, each of the walls having inside and outside surfaces and
upper and lower surfaces, the inside surfaces of the walls forming
an open core, the upper surfaces of the walls forming an upper
surface of the body, and the lower surfaces of the walls forming a
lower surface of the body, and first and second projections
extending from the lower surface of the body, the first projection
extending from the lower surface of the first side wall and the
second projection extending from the lower surface of the second
side wall, the first and second projections being spaced
equidistant between the front and rear wall inside surfaces and
adapted for placement within the cavity of an underlying block in
the retaining wall so as to provide essentially no setback
dimension between the block and the underlying block.
15. A masonry wall block as in claim 14, wherein there is
essentially no setback dimension when the first and second
projections are placed within the cavity of the underlying block in
an abutting relation to the front wall inside surface of the
underlying block.
16. A masonry wall block as in claim 14, wherein there is
essentially no setback dimension when the first and second
projections are placed within the cavity of the underlying block in
an abutting relation to the rear wall inside surface of the
underlying block.
17. A masonry wall block as in claim 14, wherein the core is spaced
equidistant between the front and rear wall outer surfaces.
18. A masonry wall block as in claim 14, wherein the core is offset
between the front and rear wall outer surfaces.
19. A masonry wall block as in claim 14, wherein the first and
second projections are spaced equidistant between the front and
rear wall outside surfaces.
20. A masonry wall block for forming a retaining wall comprising: a
body having a front wall, a rear wall, and first and second side
walls extending from the front wall to the rear wall, the front
wall having a length greater than the length of the rear wall such
that the first and second side walls converge toward one another as
they extend from the front wall toward the rear wall, each of the
walls having inside and outside surfaces and upper and lower
surfaces, the inside surfaces of the walls forming an open core,
the upper surfaces of the walls forming an upper surface of the
body, and the lower surfaces of the walls forming a lower surface
of the body, and first and second projections extending from the
lower surface of the body, the first projection extending from the
lower surface of the first side wall and the second projection
extending from the lower surface of the second side wall, the first
and second projections being adapted for placement within the
cavity of an underlying block in the retaining wall, the front wall
of the block being configured to lie adjacent the rear wall of a
laterally adjacent block in the retaining wall such that the cavity
of the block is positioned to receive the first projection of an
overlying block in the retaining wall in an abutting relation to
the inside surface of the front wall of the bock and the cavity of
the laterally adjacent block is positioned to receive the second
projection of the same overlying block in the retaining wall in an
abutting relation to the inside surface of the rear wall of the
laterally adjacent block.
21. A masonry wall block as in claim 20, wherein the front wall and
the rear wall are of equal width.
22. A masonry wall block for forming a retaining wall comprising: a
body having a front wall, a rear wall, and first and second side
walls extending from the front wall to the rear wall, the front
wall having a length greater than the length of the rear wall such
that the first and second side walls converge toward one another as
they extend from the front wall toward the rear wall, each of the
walls having inside and outside surfaces and upper and lower
surfaces, the inside surfaces of the walls forming an open core,
the upper surfaces of the walls forming an upper surface of the
body, and the lower surfaces of the walls forming a lower surface
of the body, and first and second projections extending from the
lower surface of the body, the first projection extending from the
lower surface of the first side wall and the second projection
extending from the lower surface of the second side wall, the first
and second projections being adapted for placement within the
cavity of an underlying block in the retaining wall, the front wall
of the block being configured to lie adjacent the rear wall of a
laterally adjacent block in the retaining wall such that the cavity
of the block is positioned to receive the first projection of an
overlying block in the retaining wall in an abutting relation to
the inside surface of the rear wall of the bock and the cavity of
the laterally adjacent block is positioned to receive the second
projection of the same overlying block in the retaining wall in an
abutting relation to the inside surface of the front wall of the
laterally adjacent block.
23. A masonry wall block as in claim 22, wherein the front wall and
the rear wall are of equal width.
24. A retaining wall comprising: a lower tier of individual blocks,
each block having a cavity, and an upper tier of individual blocks,
each block comprising a body having a front wall, a rear wall, and
first and second side walls, each of the walls having inside and
outside surfaces and upper and lower surfaces, the inside surfaces
of the walls forming an open core, the upper surfaces of the walls
forming an upper surface of the body, and the lower surfaces of the
walls forming a lower surface of the body, and first and second
projections extending from the lower surface of the body, the first
projection extending from the lower surface of the first side wall
and the second projection extending from the lower surface of the
second side wall, the first and second projections being spaced
equidistant between the front and rear wall inside surfaces and
adapted for placement within a cavity of an underlying block in the
retaining wall so as to provide essentially no setback dimension
between the block and the underlying block.
25. A retaining wall as in claim 24, wherein the retaining wall is
arranged in a linear configuration.
26. A retaining wall as in claim 24, wherein the retaining wall is
arranged in a curvilinear configuration.
27. A retaining wall as in claim 24, wherein the lower tier of
blocks are positioned laterally in the same direction.
28. A retaining wall as in claim 22, wherein the upper tier of
blocks are positioned laterally in the same direction.
29. A retaining wall as in claim 22, wherein the lower tier of
blocks are positioned laterally in an alternating direction.
30. A retaining wall as in claim 22, wherein the lower tier of
blocks are positioned laterally in an alternating direction.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of provisional U.S.
Patent Application Ser. No. 60/500,492, filed Sep. 5, 2003, and
entitled "Interlocking Masonry Wall Block."
FIELD OF THE INVENTION
[0002] This invention relates to a masonry block for stacking on
other like-shaped blocks in a staggered, interlocking and offset
manner to form a wall that is particularly well-suited for use as a
vertical seating wall around patios, pool decks, walkways, and the
like.
BACKGROUND OF THE INVENTION
[0003] A variety of masonry block designs have been developed for
building vertical seating walls. Wall block designs require a
mechanism for securing the blocks together to produce a stable wall
structure. Conventional interlocking masonry wall blocks are heavy
and difficult to handle. In addition, several different block
shapes must be combined to form the straight and curved sections of
a serpentine wall. The need remains for masonry wall blocks that
are cost-efficient to manufacture and easily assembled into a
stabile and durable wall.
SUMMARY OF THE INVENTION
[0004] Each block in an upper course of blocks is laid in a
staggered manner relative to a lower course so that the upper block
is placed atop two lower blocks. Single block units mate with like
units to build straight walls, inside curves, outside curves and
angle corners. Laterally adjacent blocks may be similarly aligned.
Alternatively, laterally adjacent blocks may be inversely aligned
so that the front wall of one block lies adjacent the rear wall of
the adjacent block.
[0005] According to one aspect of the invention, a masonry wall
block for forming a retaining wall comprises a body having a front
wall, a rear wall, and first and second side walls. Each of the
walls has inside and outside surfaces and upper and lower surfaces.
The inside surfaces of the walls form an open core having a width.
The upper surfaces of the walls form an upper surface of the body.
The lower surfaces of the walls form a lower surface of the body. A
first projection extends from the lower surface of the first side
wall and a second projection extends from the lower surface of the
second side wall. The core has a width less than 1.25.times. the
width of the projections. The projections are adapted for placement
within the core of an underlying block in the retaining wall.
[0006] In one embodiment, the core is offset between the front and
rear wall outer surfaces. In another embodiment, the core is
centered between the front and rear wall outer surfaces.
[0007] In one embodiment, the first and second projections are
offset between the front and rear wall inside surfaces. In another
embodiment, the first and second projections are spaced equidistant
between the front and rear wall inside surfaces.
[0008] According to another aspect of the invention, a masonry wall
block for forming a retaining wall comprises a body having a front
wall, a rear wall, and first and second side walls. Each of the
walls has inside and outside surfaces and upper and lower surfaces.
The inside surfaces of the walls form an open core having a width.
The upper surfaces of the walls form an upper surface of the body.
The lower surfaces of the walls form a lower surface of the body. A
first projection extends from the lower surface of the first side
wall and a second projection extends from the lower surface of the
second side wall. The projections are adapted for placement within
the cavity of an underlying block in the retaining wall. At least
one of the first and second side walls includes a score line
between the cavity and the respective first or second projection
that extends from the front wall outer surface to the rear wall
outer surface.
[0009] In one embodiment, the core is offset between the front and
rear wall outer surfaces. In another embodiment, the core is
centered between the front and rear wall outer surfaces.
[0010] In one embodiment, the first and second projections are
offset between the front and rear wall inside surfaces. In another
embodiment, the first and second projections are spaced equidistant
between the front and rear wall inside surfaces.
[0011] According another aspect of the invention, a masonry wall
block for forming a retaining wall comprises a body having a front
wall, a rear wall, and first and second side walls. Each of the
walls has inside and outside surfaces and upper and lower surfaces.
The inside surfaces of the walls form an open core having a width.
The upper surfaces of the walls form an upper surface of the body.
The lower surfaces of the walls form a lower surface of the body. A
first projection extends from the lower surface of the first side
wall and a second projection extends from the lower surface of the
second side wall. The projections are spaced equidistant between
the front and rear wall inside surfaces and adapted for placement
within the cavity of an underlying block in the retaining wall so
as to provide essentially no setback dimension between the block
and the underlying block.
[0012] In one embodiment, there is essentially no setback dimension
when the first and second projections are placed within the cavity
of the underlying block in an abutting relation to the front wall
inside surface of the underlying block.
[0013] In another embodiment, there is essentially no setback
dimension when the first and second projections are placed within
the cavity of the underlying block in an abutting relation to the
rear wall inside surface of the underlying block.
[0014] In one embodiment, the core is offset between the front and
rear wall outer surfaces. In another embodiment, the core is
centered between the front and rear wall outer surfaces.
[0015] In one embodiment, the first and second projections are
spaced equidistant between the front and rear wall outside
surfaces.
[0016] According to another aspect of the invention, a masonry wall
block for forming a retaining wall comprises a body having a front
wall, a rear wall, and first and second side walls that extend from
the front wall to the rear wall. The front wall has a length
greater than the length of the rear wall such that the first and
second side walls converge toward one another as they extend from
the front wall toward the rear wall. Each of the walls has inside
and outside surfaces and upper and lower surfaces. The inside
surfaces of the walls form an open core. The upper surfaces of the
walls form an upper surface of the body. The lower surfaces of the
walls form a lower surface of the body. A first projection extends
from the lower surface of the first side wall and a second
projection extends from the lower surface of the second side wall.
The first and second projections are adapted for placement within
the cavity of an underlying block in the retaining wall. The front
wall of the block is configured to lie adjacent the rear wall of a
laterally adjacent block in the retaining wall such that the cavity
of the block is positioned to receive the first projection of an
overlying block in the retaining wall in an abutting relation to
the inside surface of the front wall of the bock and the cavity of
the laterally adjacent block is positioned to receive the second
projection of the same overlying block in the retaining wall in an
abutting relation to the inside surface of the rear wall of the
laterally adjacent block.
[0017] In one embodiment, the front wall and the rear wall are of
equal width.
[0018] A masonry wall block for forming a retaining wall comprising
a body having a front wall, a rear wall, and first and second side
walls that extend from the front wall to the rear wall. The front
wall has a length greater than the length of the rear wall such
that the first and second side walls converge toward one another as
they extend from the front wall toward the rear wall. Each of the
walls has inside and outside surfaces and upper and lower surfaces.
The inside surfaces of the walls form an open core. The upper
surfaces of the walls form an upper surface of the body. The lower
surfaces of the walls form a lower surface of the body. A first
projection extends from the lower surface of the first side wall
and a second projection extends from the lower surface of the
second side wall. The first and second projections are adapted for
placement within the cavity of an underlying block in the retaining
wall. The front wall of the block is configured to lie adjacent the
rear wall of a laterally adjacent block in the retaining wall such
that the cavity of the block is positioned to receive the first
projection of an overlying block in the retaining wall in an
abutting relation to the inside surface of the rear wall of the
bock and the cavity of the laterally adjacent block is positioned
to receive the second projection of the same overlying block in the
retaining wall in an abutting relation to the inside surface of the
front wall of the laterally adjacent block.
[0019] In one embodiment, the front wall and the rear wall are of
equal width.
[0020] According to yet another aspect of the invention, a
retaining wall comprises a lower tier of individual blocks, each
block having a cavity, and an upper tier of individual blocks. Each
block in the upper tier comprises a body having a front wall, a
rear wall, and first and second side walls. Each of the walls has
inside and outside surfaces and upper and lower surfaces. The
inside surfaces of the walls form an open core having a width. The
upper surfaces of the walls form an upper surface of the body. The
lower surfaces of the walls form a lower surface of the body. A
first projection extends from the lower surface of the first side
wall and a second projection extends from the lower surface of the
second side wall. The projections are spaced equidistant between
the front and rear wall inside surfaces and adapted for placement
within the cavity of an underlying block in the retaining wall so
as to provide essentially no setback dimension between the block
and the underlying block.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a bottom perspective view of a masonry block
unit.
[0022] FIG. 2 is a top perspective view of the block shown in FIG.
1.
[0023] FIG. 3 is a bottom plan view of the block shown in FIG.
1.
[0024] FIG. 4 is a top plan view of the block shown in FIG. 1.
[0025] FIG. 5 is a front plan view of the block shown in FIG.
1.
[0026] FIG. 6 is a side view of the block shown in FIG. 1.
[0027] FIG. 7 is a perspective view of a masonry seating wall
formed from like-shaped blocks.
[0028] FIG. 8 is a top plan view illustrating a series of
laterally-adjacent blocks inversely aligned to form a straight
wall.
[0029] FIG. 9 is a top plan view illustrating the arrangement of a
series of inversely-aligned laterally-adjacent blocks to form an
angular wall.
[0030] FIG. 10 is a top plan view illustrating an alternative
arrangement of a series of inversely-aligned laterally-adjacent
blocks to form an angular wall.
[0031] FIG. 11 is a top plan view illustrating an angular wall
constructed by alternating courses arranged as in FIG. 9 with
courses arranged as in FIG. 10.
[0032] FIG. 12 is a top plan view illustrating the arrangement of a
series of similarly aligned laterally-adjacent blocks to form a
straight or linear wall.
[0033] FIG. 13 is a top plan view illustrating the arrangement of a
series of similarly aligned laterally-adjacent blocks to form a
curved wall.
[0034] FIG. 14 is a top plan view illustrating the arrangement of a
series of similarly aligned laterally-adjacent blocks to form a
wall having straight portions and curved portions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] An individual masonry block 10 for use in constructing
vertical seating walls around patios, pool decks, walkways, etc. is
shown in FIGS. 1-6. The block 10 has a main body 12 having a front
wall 14 having an outside surface 16 and an inside surface 18, a
rear wall 20 having an outside surface 22 and an inside surface 24,
and first and second side walls 26 each having an outside surface
28 and an inside surface 30. The inside surfaces 18/24/30 of the
walls 14/20/26 define an open core 32.
[0036] The upper surfaces of walls 14, 20, and 26 define an upper
surface 34 of the body 12. The lower surfaces of walls 14, 20, and
26 define a lower surface 36 of the body 12. The upper and lower
surfaces 34 and 36 are generally parallel to each other. When laid
in place on a horizontal supporting surface, the upper and lower
surfaces 34 and 36 are horizontal as well.
[0037] The front wall 14 has a length L.sub.F and the rear wall 20
has a length L.sub.R. Each side wall 26 converges toward the other
at an angle A as it extends toward the rear wall 20 such that
L.sub.F>L.sub.R, thereby providing the block 10 a generally
trapezoidal shape. The front and rear walls 14 and 20 are generally
parallel (i.e., both walls 14 and 20 are of an essentially straight
or linear configuration), and generally perpendicular to upper and
lower surfaces 34 and 36. It is contemplated, however, that either
or both of front and rear walls 14 and 20 may be of a curvilinear
configuration, e.g., convex, arcuate, or serpentine configuration
(not shown). Front and rear walls 14 and 20 are desirably both
finished (split, soft split or textured). The block 10 has a width
W.sub.B.
[0038] Desirably, at least one score line 38 is provided. In a
preferred embodiment, a pair of opposing score lines 38 are
provided. In the illustrated embodiment, the score lines 38 take
the form of a V-shaped grooves G. The score lines 38 are generally
parallel and extend from the front wall 14 to the rear wall 20. A
block 10 may be split along a score line 38 to form an end block 40
presenting a flat end surface 42, as will be explained in detail
later (see FIGS. 9-11).
[0039] Two opposing integral lug projections 44 extend from the
lower surface 36 of the block 10. In the illustrated and preferred
embodiment, a first projection 44 extends from the lower surface 36
of the first side wall 26 and the second projection 44 extends from
the lower surface 36 of the second side wall 26. Each projection 44
is desirably positioned between the score line 38 and the outside
surface 28 of the respective side wall 26. The projections 44 are
generally rounded or convex, having a radius R.sub.L, a height
H.sub.L, and a width W.sub.L. It is contemplated that the
projections 44 may take on a variety of other configurations, e.g.,
rectangular or square, to accommodate specific needs. In a
preferred embodiment, each lug projection 44 is generally centered
equidistant between the front wall inside surface 18 and the rear
wall inside surface 24 such that distance D1 and distance D2 are
essentially equal.
[0040] The open interior or core 32 extends completely through the
block 10 from the upper surface 34 to the lower surface 36. The
open core 32 does not present a trapezoidal shape as does the block
body 12, but instead has a generally elongated, rounded shape
having a length L.sub.C, width W.sub.C and radius R.sub.C.
Desirably, the width of the core 32 is only slightly larger than
the width of the projection 44, such that W.sub.C is only slightly
greater than W.sub.L. This arrangement allows for easy placement of
the projections 44 within the core 32 of an adjacent-tiered block
10 and provides a tolerance allowing for expansion, contraction, or
settling movement of the blocks 10. This arrangement also provides
sufficient tolerance for orientating the blocks 10 in various
configurations, e.g., curved walls, as will be described later. In
addition, this arrangement permits minimal forward or reverse
movement of the blocks 10 within the retaining wall, thus providing
additional stability to the wall. For example, the core 32 may have
a width W.sub.C that is less than twice the width of the
projections W.sub.L (W.sub.C<2.times.W.sub.L), and preferably
W.sub.C is less than 1.25 times W.sub.L
(W.sub.C=1.25.times.W.sub.L). In a preferred embodiment, the core
32 has a width of 11/2 inches and each lug projection 44 has a
width of 13/8 inch.
[0041] With reference to FIG. 3, the core 32 is desirably slightly
offset between the front and rear walls 14 and 20. For example, in
one embodiment, the rear wall 20 is of a slightly greater width
than the width of the front wall 14 such that distance
D3>distance D4. In this arrangement, there is no or zero setback
when the projections 44 are placed in an abutting relation with the
inside surface 24 of the rear wall 20 within the core 32 of a
similarly-aligned adjacent-tiered block 10. In an alternative
embodiment, the front wall 14 is of a slightly greater width than
the width of the rear wall 20 such that distance D4>distance D3.
In this embodiment, there is no or zero setback when the
projections 44 are placed in an abutting relation with the inside
surface 18 of the front wall 14 within the core 32 of a
similarly-aligned adjacent-tiered block.
[0042] In an alternative embodiment, the core 32 is not offset,
i.e., the front and rear walls 14 and 20 are of equal width, such
that D3=D4. In this embodiment, there is no or zero setback when
the projections 44 are placed equidistant between the front and
rear inside wall surfaces 18 and 24 within the core 32 of a
similarly-aligned adjacent-tiered block 10. In this case, it may be
desirable to slightly offset the projections 44 with respect to the
core 32 (i.e., such that D1.noteq.D2) so as to provide zero offset
when the projections 44 abut the front wall inside surface 18 or
the rear wall inside surface 24 of an adjacent-tiered block 10.
[0043] One of ordinary skill in the art should readily appreciate
that the volume of the core 32 can vary, but is preferably
maximized to decrease the weight and material cost of the block 10
without impairing the strength, integrity and manufacturability of
the block 10. Similarly, the actual shape and dimensions of the
core 32 can vary, provided the core 32 maintains the ability to
receive the lug-shaped projections 44 of another block 10, as will
be described later.
[0044] Table 1 lists dimensions for a representative
embodiment:
1 TABLE 1 Length L.sub.F of front wall 12 inches Length L.sub.R of
rear wall 9 inches Width W of block 7 inches Angle A 12.degree. Lug
height H.sub.L {fraction (5/16)} inch Lug width W.sub.L 13/8 inch
Radius of lug R.sub.L 1/4 inch Length of core L.sub.C 6 inches
Width of core W.sub.C 11/2 inches Radius of core R.sub.c 3/4 inch
D1 3/4 inch D2 3/4 inch D3 33/4 inches D4 31/4 inches Groove G 1/8
inch
[0045] The block 10 configuration enables a fastening system that
provides simple construction and automatic wall alignment. The
like-shaped blocks 10 are sized and configured to be laterally
aligned in an abutting side-by-side engagement, and vertically
aligned in a staggered, stacked manner so that one block 10 rests
atop two other blocks 10.
[0046] When arranged in this manner, the blocks form a multi-tiered
wall (W), such as the wall W shown in FIG. 7. With reference to
FIG. 8, the wall W is typically constructed one tier or course at a
time. Once a lower course 46 (represented in phantom lines in FIG.
8) is set in place, an upper course 48 (represented in solid lines
in FIG. 8) is placed on top of it. The blocks 10 forming the lower
course 46 form a generally horizontal platform upon which the upper
course 48 can be stacked.
[0047] An interlocking fit is achieved between the like-shaped
blocks 10 in adjacent upper and lower courses 48 and 46. Each block
10 in the upper course 48 is laid in a staggered manner relative to
the lower course 46 so that the upper block 10 is placed atop two
lower blocks 10. Each block 10 is also placed such that one of its
lug projections 44 extends into and is received by the open core 32
of an adjacent block 10 in an adjacent course 46 or 48. This
interlock limits forward or backward movement of blocks 10 in one
course 46 or 48 relative to the blocks 10 of an adjacent course 46
or 48. This arrangement also limits sideways or lateral movement of
blocks 10 in one course 46 or 48 relative to the blocks 10 of the
adjacent course 46 or 48.
[0048] The first course may be laid such that the lower surface 36
and projections 44 are positioned facing upward (i.e., with upper
surface 34 facing downward). Upward positioning of the projections
44 may be desirable if the first course is to be laid on a hard or
finished surface, e.g., on a patio or deck 50, as shown in FIG. 7.
In this embodiment, the subsequent courses may all be similarly
laid with the lower surface 36 and projections 44 facing upward,
such that each projection 44 extends into and is received by the
open core 32 of an adjacent upper block 10. That is, the upper
surface 34 of each block 10 in each stacked, upper course 48 is
placed on and rests on the lower surfaces 36 of the blocks 10 in
the lower course 46 upon which it is placed.
[0049] Alternatively, subsequent courses may all be laid with the
projections 44 facing downward, such that each projection 44
extends into and is received by the open core 32 of an adjacent
lower block 10. That is, the lower surface 36 of each block 10 in
each stacked, upper course 48 is placed on and rests on the upper
surfaces 34 of the blocks 10 in the lower course 46 upon which it
is placed. The final course is desirably laid with the projections
44 facing downward regardless of whether the previous courses were
laid with the projections 44 facing upward or downward to present
the flat or smooth upper surfaces 34 of the blocks 10 forming the
top course, thereby eliminating the need to cut or otherwise remove
the projections 44 from the blocks 10 forming the top course.
[0050] Alternatively, the first course may be laid with the lower
surface 36 and projections 44 positioned facing downward (i.e.,
with upper surface 34 facing upward). Downward positioning of the
projections 44 may be desirable if the first course is to be laid
on soil or other surface in which the projections 44 may be
extended to further anchor the first course blocks 10. If the first
course is laid with the projections 44 facing downward, the
subsequent courses are preferably all laid with the projections 44
facing downward. This arrangement also presents the flat or smooth
upper surfaces 34 of the blocks 10 forming the top course.
[0051] With reference again to FIG. 8, in each course, adjacent
like-shaped blocks 10 may be laterally inversely aligned so that
the front wall 14 of one block 10 lies adjacent the rear wall 20 of
the adjacent block 10. The core 32 of a block 10 is positioned to
receive the first projection 44 of an overlying block 10 and the
laterally adjacent block 10 is positioned to receive the second
projection 44 of the same overlying block 10. The placement of the
projections 44 and the core 32 with respect to the front and rear
wall outside surfaces 22 and 28 can be varied to provide no offset
dimension and to permit construction of an essentially straight or
linear wall or wall portion W.sub.L, as shown in FIG. 8.
[0052] When the core 32 is spaced essentially equidistant between
the front and rear wall outside surfaces 22 and 28, the core 32 of
a block 10 is positioned to receive the first projection 44 of an
overlying block 10 in the retaining wall W in an abutting relation
to the inside surface 24 of the front wall 14 of the bock 10 and
the core 32 of an inversely-aligned and laterally-adjacent block 10
is positioned to receive the second projection 44 of the same
overlying block 10 in an abutting relation to the inside surface 24
of the rear wall 20 of the laterally adjacent block 10.
Alternatively, when the core 32 is spaced essentially equidistant
between the front and rear wall outside surfaces 22 and 28, the
core 32 of the block 10 is positioned to receive the first
projection 44 of an overlying block 10 in the retaining wall W in
an abutting relation to the inside surface 24 of the rear wall 20
of the bock 10 and the core 32 of an inversely-aligned and
laterally-adjacent block 10 is positioned to receive the second
projection 44 of the same overlying block 10 in an abutting
relation to the inside surface 18 of the front wall 14 of the
laterally adjacent block 10.
[0053] As seen in FIGS. 9-11, laterally inversely-aligned blocks 10
may also be arranged to construct a wall W having an essentially
90.degree. angle. Laterally-adjacent blocks 10 may be broken along
a score line 38 (with broken away sections represented in phantom
in FIGS. 9 and 10) to form an end block 40 presenting a flat side
end surface 42. FIG. 9 illustrates one arrangement (C1) of blocks
10 suitable for forming an angle. FIG. 10 illustrates another
arrangement (C2) of blocks 10 suitable for forming an angle.
Beginning with either a C1 or a C2 course, C1 and C2 courses can be
alternated and staggered as shown in FIG. 11 (with the C1 course
represented in solid lines and the C2 course represented in phantom
lines) to construct an angular wall W of a desired
configuration.
[0054] As shown in FIG. 12, in each course 46 and 48, like-shaped
blocks 10 may also be laterally similarly or uniformly aligned so
that the front wall 14 of one block 10 lies adjacent the front wall
14 of the adjacent block 10. This arrangement permits the
construction of an essentially straight or linear wall or wall
portion W.sub.L in which the side walls 26 of laterally adjacent
blocks 10 define an angle B, as FIG. 12 also shows.
[0055] To accommodate a variety of landscapes and individual design
plans, it is often desirable to construct a wall W in which at
least a portion is of a curved or arcuate configuration. As seen in
FIGS. 13 and 14, like-shaped blocks 10 may also be laterally
similarly or uniformly aligned to form a curved wall portion
W.sub.C by decreasing angle B. As illustrated in FIG. 13, each side
wall 26 of a block 10 can be placed so as to contact or abut along
its entire length a side wall 26 of a laterally adjacent block 10.
In this arrangement, angle B=0.degree. and the curved portion
W.sub.C will have a minimum radius R.sub.1.
[0056] Alternatively, as illustrated in FIG. 14, blocks 10 can be
placed such that the side walls 26 of laterally adjacent blocks are
not in contact along the entire length of the laterally adjacent
side walls 26. In this arrangement the curved portion W.sub.C will
have a radius R.sub.2 greater than the minimum radius R.sub.1, such
that R.sub.2>R.sub.1. It will be readily apparent to one of
skill in the art that angle B may be selected and varied so as to
provide a desired degree of curvature.
[0057] Curved portions W.sub.C may be arranged in either a convex
or a concave manner. The degree of curvature may also be selected
to provide a low radius curve, a medium radius curve, or a high
radius curve. In addition, the blocks 10 can be arranged to
gradually or rapidly increase or decrease the radius of the
curvature to accommodate a specific setting, landscape or purpose.
It is contemplated that blocks 10 may be aligned to form a wall W
having both straight portions and curved portions W.sub.L and
W.sub.C (see FIG. 14).
[0058] With reference again to FIG. 7, the top course of blocks 10
in the wall W is preferably capped by a series of cap stones 52 to
cover the open cores 32 of the blocks 10 that form the top course
or portion of the top course. The cap stones 52 may be of similar
size and configuration to blocks 10, but without a core 32.
Alternatively, the cap stones 52 may be of an alternative size
and/or configuration otherwise adapted for placement over the top
course. The cap stones 52 can be glued or otherwise adhered to the
upper surface 34 of the top course of blocks 10, e.g., by masonry
adhesive.
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