U.S. patent application number 10/940771 was filed with the patent office on 2005-07-07 for walling product.
This patent application is currently assigned to W.J. Ladd (Concrete Products). Invention is credited to Hopson, Mathew, Ladd, Antony, Ladd, Philip.
Application Number | 20050144883 10/940771 |
Document ID | / |
Family ID | 34713776 |
Filed Date | 2005-07-07 |
United States Patent
Application |
20050144883 |
Kind Code |
A1 |
Hopson, Mathew ; et
al. |
July 7, 2005 |
Walling product
Abstract
A walling product comprising reconstituted walling material
formed as a block, in which at least one end of the block is
adapted for mutual engagement with the corresponding end of another
such block, said end providing both horizontal and vertical mating
surfaces. The ends of the blocks may be formed as tongues formed
with through-holes for receipt of a dowel, bar or pin to retain the
blocks in registration.
Inventors: |
Hopson, Mathew; (Penzance,
GB) ; Ladd, Philip; (Truro, GB) ; Ladd,
Antony; (Redruth, GB) |
Correspondence
Address: |
BANNER & WITCOFF
1001 G STREET N W
SUITE 1100
WASHINGTON
DC
20001
US
|
Assignee: |
W.J. Ladd (Concrete
Products)
Cornwall
GB
|
Family ID: |
34713776 |
Appl. No.: |
10/940771 |
Filed: |
September 15, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60530642 |
Dec 19, 2003 |
|
|
|
Current U.S.
Class: |
52/596 |
Current CPC
Class: |
E04B 2002/0267 20130101;
E04B 2002/023 20130101; E04C 1/395 20130101; E04B 2002/0271
20130101; E04B 2002/0245 20130101; E04B 2/06 20130101 |
Class at
Publication: |
052/596 |
International
Class: |
E04B 001/02 |
Claims
1. A walling product comprising reconstituted walling material
formed as a block, in which at least one end of the block is
adapted for mutual engagement with the corresponding end of another
such block, said end providing both horizontal and vertical mating
surfaces.
2. A walling product according to claim 1, in which the ends of the
blocks which are adapted for respective mutual engagement present
two vertical mating surfaces extending respectively from the upper
and lower faces of the block to a medial position, the surfaces
being longitudinally spaced apart and joined by a horizontal mating
surface.
3. A walling product according to claim 1 or claim 2, in which said
at least one end of the block is provided with a through-hole for
receiving in use a dowel, bar or pin.
4. A walling product according to claim 3, in which the end of the
block comprises a tongue, the tongue being formed with the
through-hole positioned so that the holes in two (or more) mating
blocks are in vertical alignment and registration.
5. A walling product according to any preceding claim, including
horizontal and vertical mating surfaces at each end.
6. A walling product according to any preceding claim, which the
respective ends are arranged with the tongues formed in the same
upper or lower half, whereby the block is "T" shaped.
7. A walling product according to any preceding claim, in which the
block is double-sided, whereby both side surfaces simulate an
intended walling material.
8. A kit of parts for assembly of a wall, the kit comprising blocks
according to any of claims 1 to 7 including at least one end tongue
formed with a through-hole and dowels, bars or pins for engagement
in two or more tongues arranged with through-holes in
registration.
9. A kit according to claim 8, in which the dowels, bars and pins
are formed from a plastics material.
10. A wall formed from blocks according to any of claims 1 to 7,
arranged end to end with respective ends in mutual engagement.
Description
[0001] This invention relates to walling products and in particular
provides blocks of reconstituted walling material which, when
assembled and fixed together to form a wall, has the appearance of
a wall formed from. conventional materials such as brick or natural
stone. The invention is particularly intended to relate to
decorative garden-type walling.
[0002] It is already known to provide reconstituted walling blocks
having an outer side surface simulating smaller-dimensioned walling
elements joined by mortar so that, in the finished wall, the
appearance is given as though the entire wall were made from the
smaller-dimensioned blocks joined by mortar but, in practical
terms, the appearance of the simulated mortar is almost invariably
different from that of the real mortar, with the result that the
finished wall fails to give the intended impression and, in fact,
gives just the opposite impression, it being plain to the observer
that the wall is, in fact, made from artificial materials.
Furthermore, the conventional walling blocks are inherently
unsuited for purposes other than straight walls and, additionally,
a double-sided wall must be built with a double skin of
outer-facing courses of blocks, since the reverse side faces of the
blocks are invariably plain.
[0003] It is an object of the present invention to provide a
reconstituted walling block which overcomes the disadvantages of
blocks as currently available and which enables walls such as
decorative garden walls to be built in a short time.
[0004] In one aspect, the present invention provides a walling
product comprising reconstituted walling material formed as a
block, in which at least one end of the block is adapted for mutual
engagement with the corresponding end of another such block, said
end providing both horizontal and vertical mating surfaces.
[0005] In use, blocks according to the invention may be assembled
and fixed together to provide a wall in any desired shape and
height, the mating surfaces as between adjacent blocks disguising
the join and giving the impression, in the wall as a whole, of
being made entirely from naturally occurring materials according to
the side surface configuration and colouring of the individual
blocks. Preferably, the height is restricted to that of a maximum
of two blocks.
[0006] The ends of the blocks which are adapted for respective
mutual engagement preferably present two vertical mating surfaces
extending respectively from the upper and lower faces of the block
to a medial position, the surfaces being longitudinally spaced
apart and joined by a horizontal mating surface, whereby the end of
the block presents a tongue and a recess and two blocks with such
mating surfaces can be joined in end-to-end mating relationship,
the horizontal mating surfaces being in mutual contact at half the
height of the block and the tongue of one block engaging in the
recess of the other block. The tongues may be provided with a
vertical through-hole positioned so that the holes in two (or more)
mating blocks are in vertical alignment and registration, whereby a
dowel, bar or pin, preferably formed from a plastics material, may
be inserted therethrough to secure them in mechanical engagement.
In another aspect, therefore, the invention provides a kit of parts
for assembly of a wall, the kit comprising blocks (as hereinbefore
described) including at least one end tongue formed with a
through-hole and dowels, bars or pins for engagement in two or more
tongues arranged with through-holes in registration. The dowels,
bars and pins should preferably be a reasonably close fit in the
through-holes, typically of no more than 2 mm clearance, to prevent
mis-registration of adjacent blocks.
[0007] Preferably, the mating surfaces are formed to be essentially
flat, whereby the joint between two blocks is minimised; preferably
also, the flat surface extends along the entire upper and lower
edges of the blocks, whereby the entire periphery of each block
presents a flat mating surface for engagement with other blocks
above and below as well as at each end.
[0008] Walling blocks according to the invention may be straight or
curved and preferably include horizontal and vertical mating
surfaces at each end. Corner blocks may be provided, in which the
horizontal and vertical mating surfaces are provided at respective
ends disposed orthogonally to each other. The respective ends may
be arranged with the tongues alternately disposed, that is, with
the tongue at one end being formed in the lower half of the block
and the tongue at the opposite end being formed in the upper half,
but alternatively the tongues may be formed in the same half,
whereby the block is "T"-shaped. The blocks are preferably
double-sided, whereby both side surfaces simulate an intended
walling material, such as brick or natural stone. In use, suitable
coping stones may be applied to the upper-facing edge surface of
the upper course of blocks, to provide a finished appearance.
[0009] It will be appreciated that, using walling blocks according
to the invention, walls may be constructed of any size or shape and
may be straight, curved or reverse-curved, whereby the wall has a
"snake" appearance. Walls may be used to define enclosed areas such
as circles, "D"-shapes and the like, as desired and entirely at the
discretion of the consumer.
[0010] Walling blocks according to the invention may be made from
any suitable reconstituted material, whether natural or synthetic,
held together with a suitable bonding agent. Preferably, they are
made by a casting process, each block, despite having the same
surface configuration or decoration, nevertheless giving the
appearance, in the finished wall, of a wall made from
naturally-occurring materials by a skilled craftsman. The blocks
preferably comprise a lightweight aggregate and optionally a
low-density filler or extender to reduce the weight of the finished
product, to render the blocks easier to transport and use.
[0011] Embodiments of the invention will now be described by way of
example with reference to the accompanying drawings, of which:
[0012] FIG. 1 is a perspective view of a straight walling
block;
[0013] FIG. 2 is a side elevation of a "T"-shaped straight
block;
[0014] FIG. 3 is a side elevation of an alternative straight block
with only one end formed with mating surfaces;
[0015] FIG. 4 is a perspective view of a corner block;
[0016] FIG. 5 is a fragmentary view of two straight blocks mated
together; and
[0017] FIG. 6 is a perspective view of a "D"-shaped enclosure
formed from blocks according to the invention and coping
stones.
[0018] Referring to the drawings, FIG. 1 shows a straight walling
block 10 formed in a mould from reconstituted stone, that is,
ground or comminuted stone with a suitable binder, with side faces
representing individual stone blocks 11, 12 joined together by
mortar 13. The end faces 14, 15 and upper 16 and lower edge faces
are formed substantially flat with the respective end faces and
edge faces being parallel, whereby the overall configuration is
rectangular. The block is formed with longitudinally-protruding
tongues 17, 18 which each extend respectively from the upper and
lower edges to half the height of the block and are therefore
disposed alternately. The medial edge 19 of tongue 18, and also the
corresponding edge of tongue 17, are formed with essentially flat
surfaces which meet the end surfaces orthogonally. Holes or
channels 20, 21 are formed through respective tongues 17, 18 to
receive, in use, a bar or mandrel for connecting together adjacent
blocks with their tongues engaged and the holes or channels in
registration.
[0019] FIG. 2 shows a block 22 which is generally similar to that
shown in FIG. 1 but the block is generally "T"-shaped, with the
tongues 23, 24 formed in the same half of the block, considered in
relation to its height.
[0020] FIG. 3 shown a further embodiment 25 including only one
tongue 27, the end 26 of the block being suitable for the exposed
end of a wall.
[0021] FIG. 4 shows a corner block 28 suitable for use with blocks
as shown in any of FIGS. 1 to 3, or curved blocks, to form a wall
extending in two mutually-orthogonal directions, at least as
extending initially from the corner block itself.
[0022] FIG. 5 shows the end portions of two blocks 10 as shown in
FIG. 1 joined in end-to-end relationship with their tongues in
engagement and the mating surfaces in contact; a rod or mandrel 31
is, as shown, in the process of being inserted through the holes or
apertures formed in the tongues and which are in registration,
whereby the blocks are mechanically connected together.
[0023] FIG. 6 shows a completed wall in the form of a D and
constructed from corner blocks 28 as shown in FIG. 4, straight
blocks 10 and/or 22 as shown in FIGS. 1 and 2, curved blocks
otherwise similar to those shown in FIGS. 1 and 2 and coping
stores. As illustrated, the wall is double-sided. Although stepped
joints 30 between adjacent blocks are visible in the drawing, the
joints are largely insignificant in relation to the simulated stone
blocks and the wall has the appearance of having been build from
individual natural stones joined together by mortar.
* * * * *