U.S. patent application number 11/117640 was filed with the patent office on 2005-11-17 for columnar block fence system.
Invention is credited to Dawson, William B., MacDonald, Robert A..
Application Number | 20050252147 11/117640 |
Document ID | / |
Family ID | 34968049 |
Filed Date | 2005-11-17 |
United States Patent
Application |
20050252147 |
Kind Code |
A1 |
MacDonald, Robert A. ; et
al. |
November 17, 2005 |
Columnar block fence system
Abstract
A system of columnar blocks and stacking blocks interlock with
each other in the construction of a pilaster or column and a fence
panel, respectively, for use in a fence. The columnar blocks are
generally square and the stacking blocks are generally rectangular.
The columnar block faces may contain one or more slots to give a
column an appearance of a masonry joint. Blocks have at least one
interlocking element that permits a positive connection between
courses of the blocks when the interlocking element is received in
an overlying block.
Inventors: |
MacDonald, Robert A.;
(Plymouth, MN) ; Dawson, William B.; (Medina,
MN) |
Correspondence
Address: |
POPOVICH, WILES & O'CONNELL, PA
650 THIRD AVENUE SOUTH
SUITE 600
MINNEAPOLIS
MN
55402
US
|
Family ID: |
34968049 |
Appl. No.: |
11/117640 |
Filed: |
April 28, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60566590 |
Apr 29, 2004 |
|
|
|
Current U.S.
Class: |
52/606 ;
52/745.09 |
Current CPC
Class: |
E04B 2002/0267 20130101;
E04C 1/395 20130101; E04B 2002/0217 20130101; E04B 2002/0206
20130101 |
Class at
Publication: |
052/606 ;
052/745.09 |
International
Class: |
E04B 002/00 |
Claims
What is claimed is:
1. A block system for constructing a column with a wall extending
therefrom comprising: a plurality of column blocks for forming a
column, the column blocks having an upper surface spaced apart from
an opposed lower surface, thereby defining a column block
thickness, opposed first and second side surfaces and opposed third
and fourth side surfaces extending between the upper and lower
surfaces, at least one of the side surfaces having a recessed
portion extending from the top surface to the bottom surface, the
upper and lower surfaces together with the side surfaces defining a
column block body, at least one projection extending from one of
the upper and lower surfaces, at least one indentation extending
into the other of the upper and lower surfaces, the at least one
projection and the at least one indentation being positioned such
that when the column blocks are stacked one upon another to form a
column the at least one projection of a column block in a first
course is received in the at least one indentation of a column
block in a second adjacent course; and a plurality of wall blocks
for forming a wall extending from the column, the wall blocks
having an upper surface spaced apart from an opposed lower surface,
thereby defining a wall block thickness, opposed first and second
side surfaces of the wall block extending between the upper and
lower surfaces of the wall block, opposed first and second ends of
the wall block extending between the upper and lower surfaces of
the wall block, the upper and lower surfaces of the wall block
together with the first and second side surfaces of the wall block
and the first and second ends of the wall block defining a wall
block body, one of the first and second ends of the wall block
being sized to be received in a recessed portion of a side surface
of a column block.
2. The block system according to claim 1, wherein the column blocks
are generally square.
3. The block system according to claim 1, wherein the wall blocks
are generally rectangular.
4. The block system according to claim 1, wherein the column blocks
are configured to be used with from one to four fence panels.
5. The block system according to claim 1, wherein an exposed
surface contains at least one slot.
6. The block system according to claim 1, wherein the column blocks
are configured so that, when constructing a column, the column
block in the first course is rotated 90 degrees about the vertical
axis of the column with respect to the column block in the second
adjacent course.
7. The block system according to claim 1, wherein the indentation
comprises a core.
8. The block system according to claim 7, wherein the column blocks
are configured so that, when constructing the column, vertically
aligned cores of the columns are filled with reinforcement.
9. The block system according to claim 8, wherein the reinforcement
is selected from concrete grout and rebar, steel pipe and
post-tension rods.
10. The block system according to claim 1, wherein the wall blocks
include left-hand and right-hand blocks.
11. The block system according to claim 10, wherein the wall blocks
are configured so that, when constructing a corner of the wall, at
least one projection on a left-hand block in a first course
interlocks into a core of a right-hand block in an adjacent
course.
12. A column block for forming a column, the column block
comprising: an upper surface spaced apart from an opposed lower
surface, thereby defining a column block thickness; opposed first
and second side surfaces and opposed third and fourth side surfaces
extending between the upper and lower surfaces, at least one of the
side surfaces having a recessed portion extending from the top
surface to the bottom surface, the upper and lower surfaces
together with the side surfaces defining a column block body; at
least one projection extending from one of the upper and lower
surfaces, at least one indentation extending into the other of the
upper and lower surfaces, the at least one projection and the at
least one indentation being positioned such that when the column
blocks are stacked one upon another to form a column, the at least
one projection of a column block in a first course is received in
the at least one indentation of a column block in a second adjacent
course.
13. The column block according to claim 12 that is generally
square.
14. The column block according to claim 12 configured to be used
with from one to four fence panels.
15. The column block according to claim 12, wherein an exposed
surface contains at least one slot.
16. The column block according to claim 12, wherein each block has
at least one interlocking element that permits a positive
connection between courses of the blocks when the interlocking
element is received in an overlying block.
17. The column block according to claim 12, configured so that,
when constructing a column, the column block in the first course is
rotated 90 degrees about the vertical axis of the column with
respect to the column block in the second adjacent course.
18. The column block according to claim 12, wherein the indentation
comprises a core.
19. The column block according to claim 18, wherein the column
blocks are configured so that, when constructing the column,
vertically aligned cores of the columns are filled with
reinforcement.
20. The column block according to claim 19, wherein the
reinforcement is selected from concrete grout and rebar, steel pipe
and post-tension rods.
21. The column block according to claim 12 that is generally
hollow.
22. A fence, comprising: at least one column of blocks stacked in
vertically aligned courses, wherein each block has an upper surface
spaced apart from an opposed lower surface, thereby defining a
column block thickness, opposed first and second side surfaces and
opposed third and fourth side surfaces extending between the upper
and lower surfaces, at least one of the side surfaces having a
recessed portion extending from the top surface to the bottom
surface, the upper and lower surfaces together with the side
surfaces defining a column block body, at least one projection
extending from one of the upper and lower surfaces, at least one
indentation extending into the other of the upper and lower
surfaces, the at least one projection and the at least one
indentation being positioned such that, when the column blocks are
stacked one upon another to form a column, the at least one
projection of a column block in a first course is received in the
at least one indentation of a column block in a second adjacent
course; and at least one fence panel having at least one end, the
at least one end being connected to the at least one column.
23. The fence according to claim 22, wherein the at least one
column of blocks is at least two columns of blocks, wherein the at
least one end is at least first and second ends, the first end
being connected to a first of the two columns and the second end
being connected to a second of the two columns.
24. The fence according to claim 22, wherein the column blocks are
generally square.
25. The fence according to claim 22, wherein the at least one
column is configured to be used with from one to four fence
panels.
26. The fence according to claim 22, wherein the indentation
comprises a core.
27. The fence of claim 26, wherein vertically aligned cores of the
columns are filled with reinforcement.
28. The fence of claim 26, wherein the reinforcement is selected
from concrete grout and rebar, steel pipe and post-tension rods.
Description
[0001] This application claims the benefit of provisional
application Ser. No. 60/566,590, filed Apr. 29, 2004, the contents
of which are hereby incorporated herein by reference.
FIELD OF INVENTION
[0002] A system of interlocking modular blocks for forming fence
columns and fence panels is described.
BACKGROUND OF THE INVENTION
[0003] Columnar structures used for decoration or as support for
fence panels, gates or other such structures have required a
considerable amount of skill and effort to erect. Conventional
systems use mortared masonry blocks. Columns or pillars also have
been made from stone, but this requires skilled craftspeople to
ensure proper structural completion.
[0004] Modular blocks have also been used to build columns or
pillars. Such blocks can be installed without special skill. The
advantages to such blocks are that they are a convenient size to
handle, a consistent size, and installation costs are less because
of the lack of dependence on skilled labor. Blocks known in the art
use construction adhesive or mortar to provide strength of
connection and leveling between layers of blocks and may be used
with mortar to simulate the appearance of a more conventional block
and mortar column.
[0005] An important feature of the building blocks is their
appearance. The look of weathered natural stone is very appealing
for columns and other similar structures. The art provides several
methods to produce concrete blocks having an appearance that to
varying degrees mimics the look of natural stone. According to one
well-known method, blocks are individually formed in a mold and the
surfaces are textured by removal of the mold. Additional machine
texturing processes can then be applied. The look of smooth cut
stone can also be very attractive for columns and other structures.
The smooth texture provides a more straight edge, formal, geometric
shape for the block and overall structural appearance.
[0006] A need in this art remains for blocks that can be used to
construct mortarless, sturdy, reinforceable columns that have a
desired appearance.
SUMMARY OF THE INVENTION
[0007] This invention is a system of columnar blocks and stacking
blocks configured to interlock with each other in the construction
of fence panels and of a pilaster or column, respectively, in a
fence. The columnar blocks are generally square and the stacking
blocks are generally rectangular. The columnar blocks may be
configured to be used with from one to four fence panels. Any
exposed face of the blocks (i.e., that face visible to a viewer)
preferably has a desired appearance, such as that resembling
natural stone, or smooth to give a more formal appearance. The
faces of the columnar blocks may contain one or more slots to give
the resulting column or pilaster a more aesthetic appearance, such
as that of a masonry joint. The appearance of the columnar block
faces that interlock with fence panels may be smooth or textured to
match the column finish.
[0008] The columnar blocks are provided with at least one
interlocking element that permits a positive connection between
courses of the blocks when the interlocking element is received in
an overlying block. In one embodiment, the blocks interlock when
there is a 90 degree rotation about a vertical axis of each block
with each course. Also, these blocks may be placed over a pipe that
is anchored into the ground. The core and the interlocking elements
may be shaped to accommodate such a pipe. The columnar blocks can
be used to construct a column with a natural stone-like appearance
or smooth appearance depending upon which type of block is used.
This building block system is designed to be easy to install and
structurally sound.
[0009] When asymmetrical columnar blocks are used, such as in a
corner of a wall, the location of the projections is varied so that
there is a `left-hand` and `right-hand` block, and the projections
of a `left-hand` block will interlock into the core or void of the
overlying `right-hand` block.
[0010] The sides of the columnar block are provided with recesses
into which fit the stacking blocks. The resulting block system is
easy to install and structurally sound. The interlocking system
makes the use of construction adhesive and other forms of mortar
unnecessary, though such may still be used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a columnar block according
to this invention.
[0012] FIG. 2A is a side view, FIG. 2B is a top view, and FIG. 2C
is a bottom view, respectively, of the columnar block of FIG.
1.
[0013] FIG. 3 is a perspective view of a columnar block according
to this invention.
[0014] FIG. 4 is a view of the columnar block of FIG. 1 having a
vertical reinforcement element.
[0015] FIG. 5 is a view of an alternate embodiment of the columnar
block according to this invention.
[0016] FIGS. 6 and 7 are perspective views of other embodiments of
a building block of this invention.
[0017] FIG. 8A is a side view of the block of FIG. 7.
[0018] FIG. 9A is a top view of the block of FIG. 7.
[0019] FIG. 9B is a top view of another embodiment of the block of
this invention.
[0020] FIG. 10A is a bottom view of the block of FIG. 7.
[0021] FIG. 10B is a bottom view of the block of FIG. 9B.
[0022] FIG. 11 is a partial perspective view of a corner section of
a wall formed with stacking blocks and the blocks of FIGS. 9A and
9B.
[0023] FIGS. 12 and 13 are perspective views of other embodiments
of the building block of this invention.
[0024] FIGS. 14A and 14B are top and bottom views, respectively, of
the block of FIG. 13.
[0025] FIG. 15 is a perspective view of another embodiment of a
building block of this invention.
[0026] FIG. 16 is a perspective view of a column of blocks of FIG.
15.
[0027] FIG. 17 is a top view of the block of FIG. 15 and
interlocking stacking blocks.
[0028] FIG. 18 is a perspective view of another embodiment of a
building block of this invention.
[0029] FIG. 19A is a top view and FIG. 19B is a side view of the
block of FIG. 18.
[0030] FIG. 20A is a perspective view, FIG. 20B is an end view, and
FIG. 20C is a top view of a first stacking block of this
invention.
[0031] FIG. 21A is a perspective view, FIG. 21B is an end view, and
FIG. 21C is a top view of a second stacking block of this
invention.
[0032] FIGS. 22 and 23 are partial perspective views of fence
systems of this invention.
[0033] FIG. 24 is a cross-sectional view of a fence of this
invention.
[0034] FIGS. 25A to 25D are end views of capping layers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] In this application, "upper" and "lower" refer to the
placement of a columnar block in a column and a stacking block in a
fence panel. The lower or bottom surface of blocks is the surface
that faces the ground. Subsequent courses are formed by stacking
blocks so that an interlocking element, projection, or "tongue"
from one block fits into an indentation, void, or "groove" of an
overlying block. "Top" and "bottom" surfaces are defined as those
most conventionally used for these blocks, however, the blocks can
be used with tops and bottom reversed.
[0036] The blocks of this invention may be made of a rugged,
weather resistant material, such as concrete, especially if the
columnar structure is constructed outdoors. Other suitable
materials include plastic, reinforced fibers such as fiberglass,
wood, metal and stone. Rather than being formed of a solid mass of
material, the blocks may be hollow. That is, the blocks have the
desired dimension, texture, and characteristics, but are hollow
shells. This is an advantage in saving materials and in handling
the block. Such hollow shell blocks can be formed of urethane or
concrete and by casting techniques.
[0037] The surface of the blocks may be smooth or may have a
roughened appearance, such as that of natural stone. The blocks are
formed in molds and various textures can be formed on the surface,
as is known in the art.
[0038] In typical use, the interlocking element extends above the
top surface of the columnar block and projects into an indentation
in an overlying block. In a preferred embodiment, the indentation
is the same as the core; that is, the core extends through the
thickness of the block. In one preferred embodiment, two
interlocking elements extend above the top surface of the columnar
block into the core of the overlying block, thus producing positive
interconnection between facing surfaces. In a preferred embodiment,
each successive block is rotated by 90 degrees about its vertical
axis thus causing the interlocking elements to project into the
indentation or core of the block above it. The interlocking
elements hold the columnar blocks in place and eliminate the need
for mortar when constructing the column.
[0039] For columnar blocks having a vertical axis of symmetry, the
overlying block is rotated about its vertical axis and placed on
the underlying block. The projections thus fit into the void
created by the core. For columnar blocks that are asymmetrical,
such as for a corner fence column, the blocks are not rotated as
they are stacked, but rather, `left-hand` and `right-hand` blocks
are provided, as described further below.
[0040] The faces of the blocks visible to a viewer are provided
with a desirable surface appearance. These can be textured in a
manner resulting in an appearance similar to that of natural stone,
or can be smooth to give a more formal appearance. All four faces
of the columnar block have substantially the same width and height.
One or more faces of the columnar block optionally may contain one
or more slots that will be visible in the columnar structure to
give a column of blocks a more aesthetic appearance. This
appearance may mimic mortared blocks, for example.
[0041] Rotation of each columnar block about its vertical axis also
varies the location of the slot, if present, resulting in a more
eye-pleasing pattern for the column. Rotation of the columnar
blocks as a column is built also serves to produce a straight
column. Because block molding processes may result in uneven
blocks, stacking the blocks all in the same orientation may cause a
column to tilt or lean. This problem is usually solved by shimming
the blocks to make them level. With the column blocks of this
invention, shimming is unnecessary.
[0042] The columnar block is provided with one or more recesses in
one or more sides of the block. This recess is sized to accommodate
an end of a stacking block. The column blocks and stacking blocks
together form a system of blocks that forms a fence. Depending on
the location of the recesses, a straight section, a corner section,
a T-intersection, or a universal cross column can be constructed.
The recesses in the columnar block optionally are provided with a
passageway or channel. In this way, horizontal reinforcement can be
used, if desired, to tie in a layer of stacking blocks to a
columnar block in a column.
[0043] The stacking blocks form fence sections. Suitable stacking
blocks are described in U.S. Pat. No. 6,176,049 (Crant et al.),
hereby incorporated herein by reference. The stacking blocks have
opposing top and bottom surfaces that have corresponding channels
and projections so that the blocks interlock when stacked.
[0044] Columnar blocks of this invention also may be used with
other blocks having interlocking elements, such as those described
in commonly assigned, co-pending U.S. application Ser. No. ______
entitled "Column Block System," filed on even date herewith
(Attorney Docket Number KEY1033US), which claims the benefit of
commonly assigned, co-pending U.S. Provisional application Ser. No.
60/566,528, filed Apr. 29, 2004 entitled "Column Block System,"
both of which applications are hereby incorporated herein by
reference.
[0045] Both vertically and horizontally interlocking fence systems
can be constructed with the blocks of this invention.
[0046] Turning now to the drawings, the blocks of this invention
are described. FIGS. 1 and 2 show columnar block 100a. FIG. 3 shows
columnar block 100b, which is identical to block 100a except for
the placement of interlocking elements 122a/b. FIG. 5 shows block
100c, which is similar to blocks 100a and 100b, except that
channels are added to provide for horizontal reinforcement. The
columnar blocks will be referred to generically as block 100.
[0047] Blocks 100 comprise top or upper surface 112a/b/c, bottom or
lower surface 113 a/b/c, first and second opposed sides 114 a/b/c
and 116 a/b/c, and third and fourth opposed sides 115 a/b/c and 117
a/b/c. Top surface 112 a/b/c is spaced apart from opposing lower
surface 113 a/b/c, thereby defining a block thickness. Opposed
sides are substantially the same in width and height. The top and
bottom surfaces 112 a/b/c, 113 a/b/c together with the first
through fourth sides 114 a/b/c to 117 a/b/c form block body 100
a/b/c.
[0048] The sides are provided with a desired appearance, as they
will be visible to a viewer. Side 115a/b/c is additionally provided
with trough or slot 109a/b/c. This slot is optional and is a
decorative feature. The slot mimics the appearance of a mortar
joint when a column of blocks is constructed. Sides 114 a/b/c and
116 a/b/c have recessed areas 124 a/b/c and 126 a/b/c,
respectively, located generally centrally on each block side, and
suitable for interlocking with a fence panel and/or stacking block
as described further below.
[0049] The blocks are provided with core 120 a/b/c, preferably
located in the center of the block, which extends the thickness of
the block. A core is desirable because it results in reduced weight
for the block. The core is also useful when forming a column
because vertical reinforcement can be inserted through the
vertically aligned cores to lend stability to the columnar
structure. For example, concrete grout and rebar, steel pipe, or
post-tension rods can be used to fill the core and strengthen the
structure. Various reinforcement materials are known in the
art.
[0050] Block 100c, shown in FIG. 5, has recesses 124c and 126c that
communicate with core 120c via passageways or channels 129c. The
channel is a U-shaped depression which permits horizontal
reinforcement to be used when joining a stacking block to a column
of blocks. This is described further below.
[0051] The surfaces of the block meet to form edges and corners.
The corners may be beveled, chamfered or rounded to give a more
weathered natural stone-like appearance.
[0052] Core 120a/b/c is generally rectilinear, having walls
generally parallel to the side surfaces. On opposing inside corners
of core 120 a/b/c are located two interlocking elements 122 a/b/c.
These elements extend the thickness of the block, and project above
the top surface of the block. They are essentially co-planar or
parallel with the bottom surface of the block, that is, the bottom
surface of the block is essentially co-planar or contiguous with
the bottom surfaces of these elements. Although neither the
interlocking elements nor the core need extend the thickness of the
block, typically it is simpler to manufacture the blocks this way.
In any event, the interlocking elements extend a distance above the
top surface of the block. This distance is sufficient to provide
adequate interlocking between blocks when a second columnar block
is stacked on a first columnar block.
[0053] The interlocking elements are positioned both to align
columnar blocks and lock them into place when they are stacked one
upon another. That is, blocks 100a and 100b would be used together
in a column. The position of the interlocking elements varies so
that the columnar blocks can be stacked. Block 100c might be
interlocked with corresponding similar columnar blocks (i.e.,
analogous to blocks 100b); however, block 100c can be used with
blocks 100a and 100b in a column of blocks and horizontal
reinforcement used in only one layer of the column.
[0054] In preferred embodiments, the interlocking elements are
shaped so that a pipe connecting the column to its base or
foundation can be installed vertically in the center of the
columnar block and through the center of the column. That is, as
shown in the figures, the portion of the projection facing the
center of the core is curvilinear.
[0055] FIG. 4 illustrates block 100b having vertical reinforcement
member 50. This reinforcement member, or pipe, can be made of
galvanized steel, and a column of blocks is formed around it when
constructing a fence, as described further below. Reinforcement
member 50 is tied to a column foundation (e.g., in-ground molded
concrete) by means of direct embedment or by use of a threaded
sleeve which connects to a mating thread at the end of the steel
tube.
[0056] FIGS. 6 to 11 illustrate columnar blocks 200a and 200b of
this invention. Block 200a/b is similar to block 100a/b, except
that adjacent sides, rather than opposing sides, are similar. That
is, for example, adjacent sides 214a/b and 215a/b have recessed
areas 224a/b and 225a/b. This block is for use at a corner of a
fence. Block 200a is similar to block 200b except that recesses
224b and 225b of block 200b are provided with channels for use with
horizontal reinforcement.
[0057] Blocks 200a/b comprise top or upper surface 212a/b, bottom
or lower surface 213a/b (213a not shown), first and second opposed
sides 214a/b and 216a/b, and third and fourth opposed sides 215a/b
and 217a/b. Top surface 212a/b is spaced apart from opposing lower
surface 213a/b, thereby defining a block thickness. Opposed sides
have substantially the same height and width. The top and bottom
surfaces together with the first, second, third, and fourth sides
form a block body.
[0058] Sides 216a/b and 217a/b are provided with a desired
appearance, as they will be visible to a viewer. Side 217a/b is
additionally provided with optional trough or slot 209a/b. The
blocks are provided with core 220a/b, preferably located in the
center of the block, which extends the thickness of the block.
[0059] Block 200b, shown in FIG. 7, illustrates that recesses 224b
and 225b communicate with core 220b via U-shaped channels 229b.
Side 217b is shown in FIG. 8. The edges and corners of blocks
200a/b are chamfered.
[0060] On opposing inside corners of core 220a/b are located two
interlocking elements 222a/b. These elements extend the thickness
of the columnar block, project above the top surface of the block,
and are essentially co-planar with the bottom surface of the
block.
[0061] Top 212b of block 200b is shown in FIG. 9A. This is to be
contrasted with top 212c of block 200c in FIG. 9B, which has
identical features to block 200b. Corresponding bottom views (i.e.,
213b and 213c) are shown in FIGS. 10A and 10B. These columnar
blocks differ in the placement of the interlocking projections.
These columnar blocks can be considered left-hand and right-hand
blocks, as illustrated in FIG. 11, in which the corner of a partial
wall is shown with a first course of stacking blocks 700. In this
case, block 200b is set down first, then block 200c is placed on
top of that. Interlocking projections 222b fit into the void
created by the core of block 200c. As many columnar blocks as
desired are stacked and interlocked in this manner. Stacking blocks
700 fit into the recesses in the columnar blocks' sides to form
fence sections. Both vertical and horizontal reinforcement can be
added.
[0062] FIGS. 12 and 13 illustrate perspective views of two other
columnar block embodiments. Blocks 300a and 300b are similar, each
having a recess on each side of the block. Block 300b additionally
has channels 329b coincident with the recesses to accommodate
horizontal reinforcement. These columnar blocks are for use in a
universal cross column.
[0063] Block 300a/b comprises top or upper surface 312a/b, bottom
or lower surface 313, first and second opposed sides 314a/b and
316a/b, and third and fourth opposed sides 315a/b and 317a/b. Top
surface 312a/b is spaced apart from opposing lower surface 313,
thereby defining a block thickness. The opposed sides have
substantially the same height and width and each side has
corresponding recessed areas 324a/b, 325a/b, 326a/b, and 327a/b.
The top and bottom together with the first, second, third, and
fourth sides form a block body.
[0064] Core 320a/b extends the thickness of the columnar block as
shown in the bottom view of FIG. 14A. The top view of block 300b is
shown in FIG. 14B. Core 320a/b is generally rectilinear, having
walls generally parallel to the side surfaces. On opposing inside
corners of core 320a/b are located two projections or interlocking
elements 322a/b, which project above the top surface of the
block.
[0065] Block 400 is shown in FIGS. 15 to 17. This columnar block is
similar to block 100b, except that a portion of the block has been
removed to form side void 429. The side voids are generally larger
in area, though similar in function to, the U-shaped channels of
block 100b. The creation of a larger space through the columnar
block is more desirable for some types of horizontal
reinforcement.
[0066] Block 400 comprises top or upper surface 412, bottom or
lower surface 413, first and second opposed sides 414 and 416, and
third and fourth opposed sides 415 and 417. Top surface 412 is
spaced apart from opposing lower surface 413, thereby defining a
block thickness. Opposed sides have substantially the same
width.
[0067] Optional slot 409 is located at a midpoint on side 415. The
slot results in a desirable appearance of the columnar blocks,
mimicking that of mortared blocks, and it aids in positioning the
columnar block when forming a column.
[0068] Core 420 extends the thickness of the block. Core 420 is
generally rectilinear, having walls generally parallel to the side
surfaces. On opposing inside corners of core 420 are located two
interlocking elements or projections 422. These elements extend the
thickness of the block, and project above the top surface of the
block. The bottom surface of the columnar block is essentially
co-planar or contiguous with the bottom surfaces of these
elements.
[0069] FIG. 16 shows column 475 of blocks 400. Side voids 429
provide a passageway through the columnar blocks. It should be
noted that one block 400 could be used with several blocks 100, for
example, when it is desired to reinforce a column horizontally
through one course. FIG. 17 is a top view of one course of fence
with a column formed from block 400. Vertical reinforcing member 50
is placed in the center of block 400. Stacking blocks 700 interlock
with and extend away from columnar block 400.
[0070] FIGS. 18 and 19 illustrate block 500, which is provided with
multiple cores. That is, not only is there the central block core
520, but there are additional cores in the interlocking projections
and at the corners of the block. Block 500 is similar to block
100a, in that it has recessed areas on opposing surfaces and
substantially the same profile as block 100a. The presence of
additional cores reduces the weight of the columnar block. This is
desirable if the blocks are formed from a dense material, such as
concrete, but is also useful if the block is molded from polymeric
material, for example.
[0071] Block 500 has upper surface 512, lower surface 513, first
and second opposed sides 514 and 516, and third and fourth opposed
sides 515 and 517. Opposed sides are substantially the same in
width and height. Side 515 has optional slot 509. Sides 514 and 516
have recessed areas 524 and 526, respectively, located generally
centrally on each block side. The top and side edges of the block
are chamfered.
[0072] Core 520 is located in the center of the block and extends
the thickness of the block. Core 520 is generally rectilinear,
having walls generally parallel to the side surfaces. On opposing
inside corners of core 520 are located two interlocking elements
522, each having core 532. Adjacent each block corner is core 534.
The cores can be seen in the top view in FIG. 19A and in phantom in
the side view of FIG. 19B.
[0073] The columnar blocks of this invention can be manufactured to
any desired dimension. Typically, the thickness or height is about
half the width of the columnar block. A desirable size for the
columnar blocks is about 12 inches (30.4 cm) square (i.e., the
maximum distance measured from side to side), and the thickness is
about 6 inches (15.2 cm). The depth of the recessed area is about 1
inch (2.5 cm), and its width is about 6 inches (15.2 cm) so that it
can accommodate the width of a stacking block. The U-shaped channel
typically is about 3 inches (7.6 cm) deep. Block dimensions are
selected not only to produce a pleasing shape for the desired
column, but also to permit ease of handling and installation.
[0074] Two types of stacking blocks are used to construct a panel
of a fence. As mentioned above, U.S. Pat. No. 6,176,049 (Crant et
al.), incorporated herein by reference, describes suitable stacking
blocks. A first stacking block is shown in FIGS. 20A to 20C. Block
700 has opposing top and bottom surfaces 704 and 705, opposing side
surfaces 706 and 707, and opposing end surfaces 702 and 703. The
distance between end surfaces 702 and 703 defines the length of the
stacking block. The distance between the side surfaces defines the
width, and the distance between the top and bottom defines the
thickness of the stacking block. Through the center of the stacking
block along the length is core 708 through which is a longitudinal
axis. The top surface has channels or grooves 710 adjacent each
side surface and the bottom surface has projections 712 adjacent
each side surface. When stacked, the projections on the bottom
surface of a stacking block fit in the channels in the top surface
of an underlying stacking block. Thus, these stacking blocks
interlock. The interlocking eliminates any need for mortar to join
the hollow stacking blocks 700 together.
[0075] It is to be understood that the designations "top block" or
"bottom block" is arbitrary and that the blocks could be stacked in
the opposite orientation.
[0076] Block edges may be chamfered or beveled to provide an
attractive appearance, and preferably the edge formed by the
channel or groove in the top surface with the side surface is
chamfered.
[0077] FIGS. 21A to 21C illustrate a second stacking block, which
has substantially the same dimensions as the stacking block shown
in FIGS. 20A to 20C. Block 800 has opposing top and bottom surfaces
804 and 805, opposing side surfaces 806 and 808, and opposing end
surfaces 802 and 803. The distance between end surfaces 802 and 803
defines the length of the block. The distance between the side
surfaces defines the width, and the distance between the top and
bottom defines the thickness of the stacking block. Through the
center of the block along the length is cavity 809 coincident with
a longitudinal axis. The cavity opens onto the top surface. The top
surface has channels or grooves 810 adjacent each side surface and
the bottom surface has projections 812 adjacent each side surface.
When stacked, the projections on the bottom surface of a stacking
block fit in the channels in the top surface of underlying block
700.
[0078] Stacking blocks 700 and 800 can be made in any desired
dimensions, however, a convenient and attractive size for these
blocks is about 6 inches (15.2 cm) wide and high, and 8 inches
(20.3 cm) long. The core is about 3.5 inches (8.9 cm) in diameter.
The U-shaped channel of block 800 is about 3.5 inches (8.9 cm) wide
(i.e., as measured on a line perpendicular to the longitudinal
axis). The channels and the projections are about 1 inch (2.5 cm)
wide.
[0079] FIG. 22 shows a portion of fence 900 having fence segments
905 and columns 910 and 912. Blocks 100 and 200 form the columns
and blocks 700 and 800 form the fence segments. The columns are
formed on concrete bases or foundations (shown as 901), which
typically comprise concrete and range in diameter from 18 to 24
inches (45.7 to 61 cm). Any desired size may be used to support
greater horizontal and vertical loads. The base may be formed by
using a tubular form or mold or by other methods as are known in
the art.
[0080] Base 901 is set into the ground to at least 24 inches (61
cm) or to frost depth depending on engineering requirements and
local government building codes. For example, to construct column
910, block 200b (a left hand block, such as shown in FIG. 9A), is
set in place, and then block 200c (a right hand block) is set down
on top of that. For column 912, the first column block (such as
100b) is set down and each subsequent block is rotated 90 degrees
about the vertical axis and stacked upon a lower block. Thus the
interlocking projections on the upper surface of a columnar block
below fit into the core of a block above and lock the blocks
together.
[0081] At the top of the fence is a capping layer comprising
capping blocks 902. Various capping blocks are suitable for use in
construction of a fence and are shown in FIGS. 25A to 25D. The
capping blocks cover the open areas of the blocks and provide a
finished appearance to the fence.
[0082] FIG. 23 shows a portion of fence 920 having columns 930
comprising blocks 300a and 300b and columns 940 comprising blocks
200a and 200b. The topmost block of each column is 300b and 200b,
respectively, in order to allow for horizontal reinforcement with
the top blocks of the fence panel. The fence segments 925 are at
right angles. Each column is formed on base 901. The fence will be
finished with a capping layer, such as those shown in FIGS. 25A to
25D.
[0083] FIG. 24 is a cross-sectional view of a fence segment, such
as 925 of FIG. 23, which illustrates that both stacking blocks 700
and 800 are used. FIG. 24 illustrates that the fence segment is
constructed over a base layer 903, which, along with one block
layer, is placed below grade level. This fence segment also shows
the capping layer in place, in this case capping block 902a. It
frequently is desirable to use horizontal reinforcement, such as
rebar 952 and grout or other fill material 954, in the bottom and
the top layers of the fence. The horizontal reinforcement helps to
produce a unified body of columns and fence segments and to
restrain bending of the fence segment between columns or pilasters.
Horizontal reinforcement is also used at and below grade level.
This helps transfer loads to the column and column footings the
reinforcement at grade level allows the fence segment to bridge
over soft, potentially settling soils. The top and bottom
reinforcement together lock the fence segment blocks together and
help resist individual block movement.
[0084] Stacking block 800 preferably is used in the same course as
a columnar block having a side void (block 400) or a columnar block
such as 100b, 200b, or 300b, depending upon the fence
configuration. Stacking block 700 can be used with any columnar
block, but typically would be used with blocks 100a, 200a, 300a, or
500.
[0085] FIGS. 25A to 25D illustrate various styles of capping blocks
902a to 902d each of which have recessed areas 904a to 904d,
respectively, to fit over underlying blocks. The capping blocks may
be provided in various lengths, typically of a size convenient to
handle. The style of capping layer is a matter of design choice.
Typically, several capping blocks will be used to form a capping
layer across the top of the fence. The capping layers may be made
of any material, including wood, concrete, and polymeric
materials.
[0086] Although particular embodiments have been disclosed herein
in detail, this has been done for purposes of illustration only,
and is not intended to be limiting with respect to the scope of the
claims. In particular, it is contemplated that various
substitutions, alterations and modifications may be made to the
invention without departing from the spirit and scope of the
invention as defined by the claims. For instance, the choice of
materials or variations in the shape or angles at which some of the
surfaces intersect are believed to be a matter of routine for a
person of ordinary skill in the art with knowledge of the
embodiments disclosed herein.
* * * * *