U.S. patent application number 13/037685 was filed with the patent office on 2011-09-08 for retaining wall block system.
This patent application is currently assigned to KEYSTONE RETAINING WALL SYSTEMS, INC.. Invention is credited to Robert A. MacDonald.
Application Number | 20110217127 13/037685 |
Document ID | / |
Family ID | 43771739 |
Filed Date | 2011-09-08 |
United States Patent
Application |
20110217127 |
Kind Code |
A1 |
MacDonald; Robert A. |
September 8, 2011 |
RETAINING WALL BLOCK SYSTEM
Abstract
A wall block having a block body having opposed front and rear
faces, opposed first and second side walls, and opposed and
substantially parallel top and bottom faces, one or more pin holes
that open onto the top face of the block, and one or more lugs that
extend from the bottom face, each lug having a back surface that
extends contiguously from the rear face of the block. A corner
block for use with the wall block. A retaining wall comprising a
plurality of wall blocks including at least one lower course and at
least one upper course.
Inventors: |
MacDonald; Robert A.;
(Plymouth, MN) |
Assignee: |
KEYSTONE RETAINING WALL SYSTEMS,
INC.
Bloomington
MN
|
Family ID: |
43771739 |
Appl. No.: |
13/037685 |
Filed: |
March 1, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61309650 |
Mar 2, 2010 |
|
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|
Current U.S.
Class: |
405/284 ;
52/578 |
Current CPC
Class: |
E02D 29/025
20130101 |
Class at
Publication: |
405/284 ;
52/578 |
International
Class: |
E02D 17/00 20060101
E02D017/00; E04C 1/00 20060101 E04C001/00; E02D 29/02 20060101
E02D029/02 |
Claims
1. A wall block comprising a block body having opposed front and
rear faces, opposed first and second side walls, and opposed and
substantially parallel top and bottom faces, one or more pin holes
that open onto the top face of the block, and one or more lugs that
extend from the bottom face, each lug having a back surface that
extends contiguously from the rear face of the block.
2. The wall block of claim 1, wherein the front face is
substantially parallel to the rear face.
3. The wall block of claim 1, wherein the block has a vertical
plane of symmetry.
4. The wall block of claim 1, wherein the one or more pin holes are
closer to the front face than the back face.
5. The wall block of claim 1, wherein the block comprises a pin
receiving channel that opens onto the bottom face of the block.
6. The wall block of claim 5, wherein the pin receiving channel is
substantially parallel to the front face.
7. The wall block of claim 6, wherein the pin receiving channel is
closer to the front face than to the rear face.
8. The wall block of claim 1, wherein the front face and the rear
face both have lengths and the length of the front face is greater
than the length of the rear face.
9. The wall block of claim 8, wherein at least a portion of the
side walls are angled back from the front face to the rear face
such that the portion of each side wall forms an acute angle with
the front face.
10. The wall block of claim 1, wherein the block comprises a
core.
11. The wall block of claim 1, wherein no lug extends from the
first to the second side wall.
12. The wall block of claim 1, wherein the block is made of
concrete.
13. The wall block of claim 1, wherein the block comprises at least
one pair of pin holes.
14. The wall block of claim 2, wherein the front face has a
compound shape with an angled portion which is non-orthogonal to
one or both of the first and second side walls.
15. The wall block of claim 1, wherein the block comprises two
lugs, a first lug being contiguous with the first side wall, and a
second lug being contiguous with the second side wall.
16. The wall block of claim 1, wherein the block comprises just one
lug, the lug not being contiguous with the first or second side
walls.
17. The wall block of claim 1, wherein the lug extends from 0.5 to
0.75 inch (1.27 to 1.91 cm) past the bottom face.
18. The wall block of claim 17, wherein the lug is from 0.75 to 1
inch deep.
19. The wall block of claim 15, wherein the block comprises three
lugs.
20. The wall block of claim 1, wherein the first and second side
walls have compound shapes and converge back from the front face
towards the rear face and then extend outward before meeting the
rear face.
21. A wall block comprising a block body having: opposed front and
back faces, opposed first and second side walls, and opposed and
substantially parallel top and bottom faces; the first and second
side walls both having lengths and the length of the second side
wall being less than the length of the first side wall, and the
first and second side walls being substantially parallel; one or
more pin holes that open onto the top face of the block; and a neck
that has a shorter width than the width of the block from the front
face to the rear face at a main body portion of the block, the neck
being formed by a neck surface having a length and being
substantially perpendicular to the second side wall and adjacent to
the second side wall, the second side wall, and the portion of the
front face having the same corresponding length as the neck
surface.
22. The wall block of claim 21, wherein the block comprises a pin
receiving channel that opens onto the bottom face of the block.
23. The wall block of claim 22, wherein the pin receiving channel
is substantially parallel to the front face.
24. The wall block of claim 23, wherein the pin receiving channel
is closer to the front face than to the rear face.
25. The wall block of claim 24, wherein the block comprises a
second pin receiving channel that is substantially parallel to the
first side wall.
26. The wall block of claim 24, wherein the pin receiving channel
is closer to the first side wall than to the second side wall.
27. The wall block of claim 21, wherein the block comprises two pin
holes, one pin hole being closer to the rear face than the front
face, and one pin hole being closer to the front face than to the
rear face.
28. A retaining wall comprising: a plurality of blocks including at
least one lower course and at least one upper course, at least one
block comprising a block body having opposed front and rear faces,
opposed first and second side walls, and opposed and substantially
parallel top and bottom faces, one or more pin holes that open onto
the top face of the block, and one or more lugs that extend from
the bottom face, each lug having a back surface that extends
contiguously from the rear face of the block.
29. The retaining wall of claim 28, wherein the retaining wall
further comprises a geogrid.
30. The retaining wall of claim 28, wherein the retaining wall
further comprises one or more pins.
31. The retaining wall of claim 30, wherein one or more of the pins
has a head.
32. The retaining wall of claim 28, wherein the plurality of blocks
includes blocks with differing dimensions.
33. The retaining wall of claim 28, wherein the front face of the
at least one block is substantially parallel to the rear face.
34. The retaining wall of claim 28, wherein the at least one block
has a vertical plane of symmetry.
35. The retaining wall of claim 28, wherein the one or more pin
holes of the at least one block are closer to the front face than
the back face.
36. The retaining wall of claim 28, wherein the at least one block
comprises a pin receiving channel that opens onto the bottom face
of the block.
37. The retaining wall of claim 36, wherein the pin receiving
channel is substantially parallel to the front face.
38. The retaining wall of claim 37, wherein the pin receiving
channel is closer to the front face than to the rear face.
39. The retaining wall of claim 28, wherein the front face and the
rear face of the at least one block both have lengths and the
length of the front face is greater than the length of the rear
face.
40. The retaining wall of claim 28, wherein the at least one block
comprises a core.
41. The retaining wall of claim 28, wherein no lug of the at least
one block extends from the first to the second side wall.
42. The retaining wall of claim 28, wherein the at least one block
is made of concrete.
43. The retaining wall of claim 28, wherein the at least one block
comprises at least one pair of pin holes.
44. The retaining wall of claim 28, wherein the at least one block
comprises two lugs, a first lug being contiguous with the first
side wall, and a second lug being contiguous with the second side
wall.
45. The retaining wall of claim 28, wherein the at least one block
comprises just one lug, the lug not being contiguous with the first
or second side walls.
46. The retaining wall of claim 44, wherein the at least one block
comprises three lugs.
47. The retaining wall of claim 28, wherein the first and second
side walls of the at least one block have compound shapes and
converge back from the front face towards the rear face and then
extend outward before meeting the rear face.
48. The retaining wall of claim 28, wherein the retaining wall
further comprises at least one block of a second block type, the
second block type comprising a block body having: opposed front and
back faces, opposed first and second side walls, and opposed and
substantially parallel top and bottom faces; the first and second
side walls both having lengths and the length of the second side
wall being less than the length of the first side wall, and the
first and second side walls being substantially parallel; one or
more pin holes that open onto the top face of the block; and a neck
that has a shorter width than the width of the block from the front
face to the rear face at a main body portion of the block, the neck
being formed by a neck surface having a length and being
substantially perpendicular to the second side wall and adjacent to
the second side wall, the second side wall, and the portion of the
front face having the same corresponding length as the neck
surface.
49. The retaining wall of claim 48, wherein the second block type
comprises a pin receiving channel that opens onto the bottom face
of the block.
50. The retaining wall of claim 49, wherein the pin receiving
channel of the second block type is substantially parallel to the
front face.
51. The retaining wall of claim 50, wherein the pin receiving
channel of the second block type is closer to the front face than
to the rear face.
52. The retaining wall of claim 51, wherein the second block type
comprises a second pin receiving channel that is substantially
parallel to the first side wall.
53. The retaining wall of claim 52, wherein the second block type
pin receiving channel is closer to the first side wall than to the
second side wall.
54. The retaining wall of claim 48, wherein the second block type
block comprises two pin holes, one pin hole being closer to the
rear face than the front face, and one pin hole being closer to the
front face than to the rear face.
Description
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 61/309,650, filed Mar. 2, 2010, entitled
"Retaining Wall Block System", the contents of which are hereby
incorporated by reference herein.
FIELD OF THE INVENTION
[0002] This invention relates generally to retaining wall blocks
and retaining walls constructed from such blocks. In particular,
this invention relates to a retaining wall block system having a
dual connection feature that allows the connection of blocks in the
wall using a pinning system and/or a lug system. The pinning system
is used to interconnect blocks in upper and lower courses and
additionally used as a geogrid soil reinforcement connection
element. The lug system is used to connect and align blocks by
course. The pinning and lug systems prevent block displacement from
retaining forces and enhance the structural integrity of the
retaining wall constructed.
BACKGROUND OF THE INVENTION
[0003] Retaining walls are used in various landscaping projects and
are available in a wide variety of styles. Numerous methods and
materials exist for the construction of retaining walls. Such
methods include the use of natural stone, poured concrete, precast
panels, masonry, and landscape timbers or railroad ties.
[0004] In recent years, segmental concrete retaining wall units,
which are dry stacked (i.e., built without the use of mortar), have
become widely accepted in the construction of retaining walls. An
example of such a unit is described in U.S. Pat. No. Re 34,314,
which issued to Forsberg (Forsberg '314). Such retaining wall units
have gained popularity because they are mass produced and,
consequently, relatively inexpensive. They are structurally sound,
easy and relatively inexpensive to install, and couple the
durability of concrete with the attractiveness of various
architectural finishes. The retaining wall system described in
Forsberg '314 has been particularly successful because of its use
of a block design that includes, among other design elements, a
unique pinning system that interlocks and aligns the retaining wall
units, thereby providing structural strength and allowing efficient
installation. This system is advantageous in the construction of
larger walls, when combined with the use of geogrids hooked over
the pins, as described in U.S. Pat. No. 4,914,876 to Forsberg
('876).
[0005] The shape of the block is also an important feature during
installation of a retaining wall. Forsberg '876 illustrates a
fairly complex shape for a retaining wall block which is
particularly advantageous in the construction of curved walls. The
block is symmetrical about a vertical plane which bisects the block
at a midway point through the front and back faces.
[0006] Many commercially available blocks are symmetrical about a
plane bisecting the front and back surfaces. Typically such blocks
have planes rather than axes of symmetry, as there are differences
between the top and bottom surfaces of such blocks. Clearly, blocks
that are substantially square or rectangular (i.e., each surface
being joined to another at an orthogonal angle) exhibit a great
deal of symmetry. Other blocks are more complex in shape and
exhibit only one vertical plane of symmetry. For example, U.S. Pat.
No. 5,711,130 (Shatley) illustrates a block having substantially
parallel front and back faces and non-parallel, mirror-image side
wall surfaces. That is, there is a mirror plane of symmetry that
vertically bisects the block. U.S. Pat. Nos. 5,598,679 (Orton et
al.) and 5,294,216 (Sievert) illustrate a type of block having
parallel front and back faces and non-parallel, converging side
surfaces. The term "converging side surfaces" means that the side
walls of the blocks converge as they approach the rear of the
block. Such blocks are also symmetrical about a vertical plane that
passes through the front and back surfaces.
[0007] There are advantages to having non-parallel surfaces on
these blocks when constructing a retaining wall. The angles formed
by these side surfaces permits construction of curvilinear walls,
and moreover, permit the amount of curvature to vary according to
the terrain and desired appearance of the retaining wall.
[0008] Retaining wall block systems are generally provided with
some means to connect blocks in adjacent courses of the wall, such
as the pinning system discussed above in connection with Forsberg
'876. Alternatively, numerous block designs have used a shear
connector embodied in the block's shape to align the blocks with a
setback, or batter. A common form of such shear connectors is a
rear, downwardly projecting lip or flange. In forming a
multi-course wall, the blocks are placed such that the flanges
contact the upper back edge of the blocks located in the course
below. As such, blocks having flanges are caused to become aligned
with the blocks positioned below, while at the same time providing
a degree of resistance against displacement of individual blocks by
earth pressures. In walls formed using blocks of this type, the
rear flanges of the blocks cause the wall to slope backward at an
angle which is predetermined by the width of the flanges.
[0009] Retaining walls using blocks having a rear flange are well
known in the art. For example, U.S. Pat. No. 2,313,363 (Schmitt)
describes an early use of a retaining wall block with a rear
flange. More recently, U.S. Pat. No. 5,294,216 (Sievert) describes
a geogrid reinforced retaining wall constructed with retaining wall
blocks having rear flanges. Such blocks function adequately for
small walls where in most cases soil reinforcement is not necessary
because they are relatively simple to install and require no
special pieces for capping the top course of the wall. In some
cases, geogrid may be used to allow these walls to be built to
greater heights due to the soil reinforcing principles of geogrid
design. Again these walls will be limited in height due to the
minimal connection strength of the lip and geogrid and the
potential for the lips to abraid and cut the geogrid. These blocks
are not generally desirable for use in taller retaining walls where
soil reinforcement with a positive connection to the wall is
necessary.
[0010] It would be desirable to provide a system of blocks for
constructing a retaining wall that combines the ease of
installation of modern segmental retaining walls with the
attractive appearance of a natural stone wall composed of stones of
varying sizes. The block system should be efficient to produce,
require a minimal number of different block shapes and allow the
construction of walls with 90 degree corners, and the construction
of freestanding walls with a desirable natural appearance. It would
also be desirable to provide a retaining wall system that allowed
an aesthetically pleasing randomness of appearance by varying the
size of blocks used in the construction of the structure.
[0011] It would further be highly desirable to have a wall block
system which can be used to build a retaining wall using either a
rear flanged block or a pin connection between courses, depending
on the requirements of the project. Such a unit would also be
desirable from a production and distribution view point, because
the same block design could be used in multiple wall applications,
thus reducing the need to produce specialty units, as well as the
need to maintain separate inventories of pinned and rear flanged
products.
[0012] In view of the above, a need exists for a wall block system
including a retaining wall block having features of both a rear
flange for alignment of the units in a wall and connection of the
units and a pinning system for positive connection to the geogrid
soil reinforcing material. Further a need exists for a retaining
wall block that may be constructed using a rear flange connection
and a pinning system for use with a geogrid for walls or wall
sections where soil reinforcement is required for structural
soundness.
SUMMARY OF THE INVENTION
[0013] The invention provides a wall block comprising a block body
having opposed front and rear faces, opposed first and second side
walls, and opposed and substantially parallel top and bottom faces,
one or more pin holes that open onto the top face of the block, and
one or more lugs that extend from the bottom face, each lug having
a back surface that extends contiguously from the rear face of the
block.
[0014] The invention provides a wall block comprising a block body
having: opposed front and back faces, opposed first and second side
walls, and opposed and substantially parallel top and bottom faces;
the first and second side walls both having lengths and the length
of the second side wall being less than the length of the first
side wall, and the first and second side walls being substantially
parallel; one or more pin holes that open onto the top face of the
block; and a neck that has a shorter width than the width of the
block from the front face to the rear face at a main body portion
of the block, the neck being formed by a neck surface having a
length and being substantially perpendicular to the second side
wall and adjacent to the second side wall, the second side wall,
and the portion of the front face having the same corresponding
length as the neck surface.
[0015] The invention provides a retaining wall comprising: a
plurality of blocks including at least one lower course and at
least one upper course, at least one block comprising a block body
having opposed front and rear faces, opposed first and second side
walls, and opposed and substantially parallel top and bottom faces,
one or more pin holes that open onto the top face of the block, and
one or more lugs that extend from the bottom face, each lug having
a back surface that extends contiguously from the rear face of the
block.
[0016] The present invention relates to a method of constructing a
retaining wall having a dual connection feature that allows the
connection of blocks in the wall using a lug system and/or a
pinning system. The lug system is used to connect and align blocks
by course. The pinning system is used to interconnect blocks in
upper and lower courses and is additionally used as a geogrid soil
reinforcement connection element. The pinning and lug systems
prevent block displacement from retaining forces and enhance the
structural integrity of the retaining wall constructed.
[0017] The present invention also relates to a wall block that is
provided with a lug or multiple lugs to enhance the structural
integrity of a structure made with the blocks and to also align the
blocks in the structure being constructed. The wall block is also
provided with pin holes and a pin receiving channel, the pin holes
of a block in a lower course of the wall receive a shaft or base of
a pin and the pin receiving channel of a block in an upper course
of the wall receive the head or top of the pin thereby interlocking
the blocks in the upper and lower courses. When the pinning system
is utilized a layer of soil reinforcement material may be laid over
the pins and pulled taut. The next course of block is placed on the
lower course with the head or top of the pins being received in the
pin receiving channel of the upper course providing additional
securement of the soil reinforcement material to the retaining
wall. Multiple embodiments of the block, lug system and pinning
system are disclosed.
[0018] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory and are intended to provide further explanation of
the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] A preferred form of the present invention will now be
described by way of example with reference to the accompanying
drawings.
[0020] FIGS. 1 to 5 are top perspective, side, top, bottom and back
views, respectively, of an embodiment of a wall block of the
present invention.
[0021] FIGS. 6 and 7 are bottom perspective and bottom views,
respectively, of a second embodiment of a wall block of the present
invention.
[0022] FIGS. 8 and 9 are front perspective and bottom views,
respectively, of a third embodiment of a wall block of the present
invention.
[0023] FIGS. 10 to 13 are top perspective, side, back and bottom
views, respectively, of an embodiment of a corner block of the
present invention.
[0024] FIGS. 14 to 16 are front perspective, back perspective and
cross-sectional side views, respectively, of a wall constructed
with the blocks of the present invention.
[0025] FIG. 17 is a cross sectional side view of a wall constructed
with the blocks of the present invention
[0026] FIGS. 18 and 19 are front perspective and back perspective
views, respectively, of a wall constructed with the blocks of the
present invention.
[0027] FIG. 20 is a front perspective of a curved wall constructed
with the blocks of the present invention.
[0028] FIGS. 21 and 22 are front perspective and back perspective
views, respectively, of a wall constructed with the blocks of the
present invention, shown in a 90 degree corner layout.
[0029] FIGS. 23 and 24 are front perspective and bottom views,
respectively, of an alternative embodiment of a wall block of the
present invention.
[0030] FIGS. 25 and 26 are top perspective and bottom perspective
views, respectively, of an alternative embodiment of a wall block
of the present invention.
[0031] FIG. 27 is a bottom perspective view of an alternative
embodiment of a wall block of the present invention.
[0032] FIG. 28 is a front perspective view of a portion of a wall
constructed with the blocks of FIGS. 23 and 24.
[0033] FIG. 29 is a front perspective view of a portion of a
concave wall constructed with the blocks of FIGS. 25 and 26.
[0034] FIG. 30 is a front perspective view of a portion of a convex
wall constructed with the blocks of FIGS. 25 and 26.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] In this application, "upper" and "lower" refer to the
placement of the block in a retaining wall. The lower surface faces
down, that is, it is placed such that it faces the ground. In
forming a retaining wall, one row of blocks is laid down, forming a
course. A second course is laid on top of this by positioning the
lower surface of one block on the upper surface of another
block.
[0036] The retaining wall blocks of this invention are symmetrical
about a vertical plane of symmetry. The blocks are provided with
pin holes, a pin receiving channel, and at least one core which
serve to decrease the weight of the block while maintaining its
strength while also providing ease of construction of a retaining
wall. The blocks are also provided with a lug(s). The location,
shape, and size of the pin holes, pin receiving channel, lugs and
core are selected to maximize the strength of the block, as
described by reference to the drawings. It is also to be understood
that the pin holes, pin receiving channels and lugs in addition to
pins described below could also be used on different block types
and block shapes to form different walls and that the block shown
with these features does not limit the scope of the invention.
[0037] The invention provides a wall block comprising a block body
having opposed front and rear faces, opposed first and second side
walls, and opposed and substantially parallel top and bottom faces,
one or more pin holes that open onto the top face of the block, and
one or more lugs that extend from the bottom face, each lug having
a back surface that extends contiguously from the rear face of the
block. In one embodiment, wherein the front face is substantially
parallel to the rear face. In an embodiment, wherein the block has
a vertical plane of symmetry. In an embodiment, one or more pin
holes are closer to the front face than the back face. In an
embodiment, the block comprises a pin receiving channel that opens
onto the bottom face of the block. In an embodiment, the pin
receiving channel is substantially parallel to the front face. In
an embodiment, the pin receiving channel is closer to the front
face than to the rear face.
[0038] In one embodiment, the front face and the rear face both
have lengths and the length of the front face is greater than the
length of the rear face. In an embodiment, at least a portion of
the side walls are angled back from the front face to the rear face
such that the portion of each side wall forms an acute angle with
the front face. In one embodiment, the block comprises a core. In
an embodiment, no lug extends from the first to the second side
wall. In one embodiment, the block is made of concrete. In an
embodiment, the block comprises at least one pair of pin holes. In
an embodiment, the front face has a compound shape with an angled
portion which is non-orthogonal to one or both of the first and
second side walls.
[0039] In one embodiment, wherein the block comprises two lugs, a
first lug being contiguous with the first side wall, and a second
lug being contiguous with the second side wall. In an embodiment,
the block comprises just one lug, the lug not being contiguous with
the first or second side walls. In an embodiment, the lug extends
from 0.5 to 0.75 inch (1.27 to 1.91 cm) past the bottom face. In an
embodiment, the lug is from 0.75 to 1 inch deep. In one embodiment,
the block comprises three lugs. In an embodiment, the first and
second side walls have compound shapes and converge back from the
front face towards the rear face and then extend outward before
meeting the rear face.
[0040] The invention provides a wall block comprising a block body
having: opposed front and back faces, opposed first and second side
walls, and opposed and substantially parallel top and bottom faces;
the first and second side walls both having lengths and the length
of the second side wall being less than the length of the first
side wall, and the first and second side walls being substantially
parallel; one or more pin holes that open onto the top face of the
block; and a neck that has a shorter width than the width of the
block from the front face to the rear face at a main body portion
of the block, the neck being formed by a neck surface having a
length and being substantially perpendicular to the second side
wall and adjacent to the second side wall, the second side wall,
and the portion of the front face having the same corresponding
length as the neck surface. In an embodiment, the block comprises a
pin receiving channel that opens onto the bottom face of the block.
In an embodiment, the pin receiving channel is substantially
parallel to the front face. In one embodiment, the pin receiving
channel is closer to the front face than to the rear face. In one
embodiment, the block comprises a second pin receiving channel that
is substantially parallel to the first side wall. In one
embodiment, the pin receiving channel is closer to the first side
wall than to the second side wall. In an embodiment, the block
comprises two pin holes, one pin hole being closer to the rear face
than the front face, and one pin hole being closer to the front
face than to the rear face.
[0041] The invention provides a retaining wall comprising: a
plurality of blocks including at least one lower course and at
least one upper course, at least one block comprising a block body
having opposed front and rear faces, opposed first and second side
walls, and opposed and substantially parallel top and bottom faces,
one or more pin holes that open onto the top face of the block, and
one or more lugs that extend from the bottom face, each lug having
a back surface that extends contiguously from the rear face of the
block. In one embodiment, the retaining wall further comprises a
geogrid. In an embodiment, the retaining wall further comprises one
or more pins, which may have a head. In one embodiment, the
plurality of blocks includes blocks with differing dimensions.
[0042] In an embodiment, the front face of the at least one block
is substantially parallel to the rear face. In an embodiment, the
at least one block has a vertical plane of symmetry. In an
embodiment, the one or more pin holes of the at least one block are
closer to the front face than the back face. In an embodiment, the
at least one block comprises a pin receiving channel that opens
onto the bottom face of the block. In an embodiment, the pin
receiving channel is substantially parallel to the front face. In
an embodiment, the pin receiving channel is closer to the front
face than to the rear face.
[0043] In one embodiment, the front face and the rear face of the
at least one block both have lengths and the length of the front
face is greater than the length of the rear face. In an embodiment,
the at least one block comprises a core. In an embodiment, no lug
of the at least one block extends from the first to the second side
wall. In an embodiment, the at least one block is made of concrete.
In an embodiment, the at least one block comprises at least one
pair of pin holes.
[0044] In one embodiment, the at least one block comprises two
lugs, a first lug being contiguous with the first side wall, and a
second lug being contiguous with the second side wall. In an
embodiment, the at least one block comprises just one lug, the lug
not being contiguous with the first or second side walls. In an
embodiment, the at least one block comprises three lugs. In an
embodiment, the first and second side walls of the at least one
block have compound shapes and converge back from the front face
towards the rear face and then extend outward before meeting the
rear face.
[0045] In an embodiment, wherein the retaining wall further
comprises at least one block of a second block type, the second
block type comprising a block body having: opposed front and back
faces, opposed first and second side walls, and opposed and
substantially parallel top and bottom faces; the first and second
side walls both having lengths and the length of the second side
wall being less than the length of the first side wall, and the
first and second side walls being substantially parallel; one or
more pin holes that open onto the top face of the block; and a neck
that has a shorter width than the width of the block from the front
face to the rear face at a main body portion of the block, the neck
being formed by a neck surface having a length and being
substantially perpendicular to the second side wall and adjacent to
the second side wall, the second side wall, and the portion of the
front face having the same corresponding length as the neck
surface. In an embodiment, the second block type comprises a pin
receiving channel that opens onto the bottom face of the block. In
an embodiment, the pin receiving channel of the second block type
is substantially parallel to the front face. In an embodiment, the
pin receiving channel of the second block type is closer to the
front face than to the rear face. In an embodiment, the second
block type comprises a second pin receiving channel that is
substantially parallel to the first side wall. In an embodiment,
the second block type pin receiving channel is closer to the first
side wall than to the second side wall. In an embodiment, the
second block type block comprises two pin holes, one pin hole being
closer to the rear face than the front face, and one pin hole being
closer to the front face than to the rear face.
[0046] An embodiment of the retaining wall block is shown in FIGS.
1 to 5. Block 100 is made of a rugged, weather resistant material,
preferably (and typically) zero-slump molded concrete. Other
suitable materials include plastic, reinforced fibers, wood, metal
and stone. Block 100 has parallel top face 102 and bottom face 103,
front face 104, rear face 105 and first and second side walls 106
and 107. Front face 104 and rear face 105 each extend from top face
102 to bottom face 103. Side walls 106 and 107 extend from top face
102 to bottom face 103, converging from front face 104 toward rear
face 105. Front face 104 may be of a compound shape with angled
portions 111 which are non-orthogonal to side walls 106 and 107 and
to portion 112 which is parallel with rear face 105. Block 100 is
generally symmetrical about vertical plane of symmetry S.
[0047] Block 100 comprises body portion 108, back portion 109 and
neck portions 110 which connect body portion 108 to back portion
109. Front face 104 forms part of body portion 108, while rear face
105 forms part of back portion 109. The body, back and neck
portions 108, 109, and 110 each extend between top and bottom faces
102 and 103 and between first and second side walls 106 and 107.
Opening or core 114 may extend through neck portion 110 from top
surface 102 to bottom face 103, or may only extend part of the way
through block 100 (for example, open to top surface 102 but closed
at bottom surface 103). Core 114 reduces the weight of block 100;
lower block weight is both a manufacturing advantage and a
constructional advantage when building a wall from the wall blocks
as it reduces cost due to less material and makes lifting of the
blocks easier.
[0048] First and second pin holes 118 are located in body portion
108 and extend from top face 102 to bottom face 103, i.e., opening
onto both top and bottom surfaces. Pin hole depressions 119 located
on the bottom face of the body portion 108 are formed from a pin
hole forming member or bridge (not shown) which is mounted to a
side wall or liner of a mold cavity. During the manufacturing of
block 100, concrete or other desired material settles around the
pin hole forming member and is allowed to set, the block is then
stripped from the mold cavity, forming pin hole 118 and pin hole
depression 119. The pin hole interior surfaces may be tapered from
narrower to wider from the top surface to the bottom surface or its
interior surfaces may be non-tapered or plumb. This taper of the
surfaces of the pin holes is used in the manufacturing phase to
help ease the removal of the block unit from the mold. The taper
creates a draft angle which helps strip the pin hole forming core
with greater ease from the block in the mold while helping to
maintain the integrity of the shape of the pin hole. The pin holes
118 are positioned away from the line of symmetry S and towards
side walls 106 and 107. It should be noted that additional pin
holes can be provided, if desired, so as to provide for further
choices of predetermined setback when building a wall.
Additionally, the location of the pin holes in the body of the
block may be varied as desired.
[0049] Pin holes are sized to receive pin 50 which is shown in FIG.
3. Pin 50 has a shaft 51 which is placed into a pin hole of the top
surface of block 100 in a lower course of blocks when constructing
a wall. Pin 50 also has a head 52, and may have a larger diameter
than the shaft 51 and may also be tapered, square, round or any
other desired shape. Additionally the shaft 51 of the pin may be
circular, square or any other desired shape as well. In this
manner, the pin inserted into a pinhole on a lower course of blocks
in a wall engages a pin receiving channel of a block in an upper
course. This results in an interlocking of the blocks with a
predetermined setback. It is to be understood that the shape of the
pin is not limiting and could be for example uniformly shaped with
no head or could have any other number of features.
[0050] Bottom surface 103 has pin receiving channel 130 located in
body portion 108. Receiving channel 130 may extend the entire
length of the body portion as shown in FIG. 4 and open onto the
surfaces of side walls 106 and 107. Pin receiving channel 130 may
be of sufficient width and depth as to accommodate the head 52 of
pin 50. It should be noted that the shape, width and length of the
channel can vary depending upon the application and could for
example only extend a portion of the length of body portion 108 or
may open onto only one of side walls 106 or 107 or may open onto
neither side wall.
[0051] Block 100 has two lugs 120 located on back portion 109 which
extend from the rear surface 105 downward past the bottom face 103
of the block. The lugs have a front surface 122, a bottom surface
123 and a back surface 124 that extends contiguously from the rear
face 105 of the block. The lugs provide an earthen retaining
structure constructed with blocks 100, and a predetermined amount
of setback, thus lugs 120 may have various dimensions, depending on
the desired setback for walls constructed of the blocks. In one
embodiment of the present invention, lugs 120 extend approximately
1/2 to 3/4 of an inch (1.27 to 1.19 cm) past the bottom face 103
and the lugs are approximately 3/4 of an inch to 1 inch deep (1.91
to 2.54 cm). It should be noted that the dimensions of the lug are
not limited and can have any dimension as desired.
[0052] Lugs 120 also serve to enhance the structural integrity of a
retaining structure made with the blocks of the present invention.
Front surface 122 of lugs 120 of a block in an upper course of a
structure abut the rear face 103 of a block in a lower course of a
structure. This abutment helps to prevent retaining forces from
displacing a block in an upper course over a block in a lower
course. Not only does this abutment help to ensure structural
stability it also increases the aesthetic value of the structure by
ensuring a more uniform setback for the structure being produced.
It should be noted that block 100 may be manufactured with
additional lugs as desired (or fewer lugs). Also the size and shape
of the lugs are not limiting and may have any desired shape or size
depending upon the application.
[0053] Block 100 is manufactured in the mold with the bottom
surface facing up. A channel forming element is attached at the top
stripping shoe of the mold and imparts or presses the pin receiving
channel 130 into the bottom face 103 of the block (top surface when
sitting inside the mold) as the material inside the mold forms to
the channel projecting element. The channel forming element is then
removed when the stripping shoe is vertically pulled upward and
away from the molded unit and the block is stripped from the mold
with the pin receiving channel formed into the bottom surface of
the block.
[0054] Though the blocks illustrated in the FIGS. 1 to 5 may have
various dimensions, block 100 typically has a height (i.e., the
distance between surfaces 102 and 103) of about 6 inches (15.2 cm),
a body length (i.e., the distance from side wall 106 to side wall
107) of about 10 inches (25.4 cm) and a width (i.e., the distance
from front face 104 to rear face 105) of about 10.5 inches (26.7
cm).
[0055] An alternative embodiment of the block is shown in FIGS. 6
and 7. Block 200 is substantially similar to block 100 except that
the length of block 200, (i.e., the distance from side wall 206 to
side wall 207) is less than the length of block 100. Additionally,
block 200 has been manufactured with only one lug 220 on bottom
face 203. Front face 204 has been provided with an optional
pattern. It should be noted that any design or texture may be
imparted onto any block surface of the present invention as
desired. For example, a roughened surface, such as the appearance
of natural stone, is a desirable appearance and can be formed
during the molding process with liners as known in the art.
[0056] An alternative embodiment of the block is shown in FIGS. 8
and 9. Block 300 is substantially similar to block 100 except that
the length of block 300, (i.e., the distance from side wall 306 to
side wall 307) is greater than the length of block 100.
Additionally, block 300 has been manufactured with three lugs 320
on bottom face 303. Front face 304 has been provided with an
optional pattern and is parallel rear face 305. First and second
pin holes 318 are located in body portion 308. Bottom surface 303
has pin receiving channel 330 located in body portion 308.
[0057] FIGS. 10 to 13 illustrate a corner block of the present
invention. Corner block 400 comprises opposing and substantially
parallel upper or top and lower or bottom faces 402 and 403
respectively, and opposing front and back faces 404 and 405,
respectively. Corner block 400 also comprises opposing side
surfaces 410 and 412. Rear face 405 is of a compound shape and
includes surface 415 which is parallel with front face 404, surface
414 which is substantially parallel with side surfaces 410 and 412,
and surface 413 which is substantially parallel with front face
404. Neck 416 is formed from surface 415 and the corresponding
length of surface 415 on front face 404, in addition to side
surface 410. Front face 404 and rear face 405 each extend from top
surface 402 to bottom surface 403, and side wall surfaces or ends
410 and 412 each extend from top surface 402 to bottom surface 403
and from front face 404 to rear face 405.
[0058] Block 400 further comprises core 417 and pin holes 418 which
extend the full width of the block. The lower surface of each block
has pin hole depressions 419 which result from the attachment of
pin hole forming members (not shown) to the division liner of the
mold box to form the pin holes in the mold. This may be used
instead of a core bar placed across a top plate (not shown) of the
mold which may impart a slight groove, channel or indentation along
the surface of the corner block. The bottom face of block 400 also
has pin receiving channel 430 which is parallel with front face 404
and pin receiving channel 440 which is parallel with side surface
412. Pin receiving channel 430 opens onto side surface 410 and may
extend the majority of the length of the front face of the corner
block. Pin receiving channel 440 opens onto rear surface 405 and
may extend the majority of the length of side face 412.
[0059] Corner blocks 400 are manufactured in a mold box which
produces two or more corner blocks 400(r) and 400(l) which are
mirror images of one another, thus they have a right and left
handed orientation, respectively. Front surface 404 and side
surface 412 will be visually exposed in the construction of a
structure and thus the left handed and right handed orientation is
beneficial when constructing a wall with a corner so as to offset
each course from another adjacent course in a structure as
described below.
[0060] Though block 400 may have various dimensions, typical
dimensions of this block are about 6 inches (15.2 cm) wide (i.e.,
the width of side surface 412), 18 inches (45.7 cm) long (i.e., the
length of front face 404), and 8 inches (20.3 cm) thick (i.e., the
thickness between the opposing upper and lower surfaces). These
dimensions are generally smaller than the dimensions of the blocks
used to form the retaining wall. Two corner blocks may be formed in
a mold box, one with a right handed configuration and one with a
left handed configuration.
[0061] FIGS. 14 and 15 illustrate perspective views of retaining
wall 500 made from block 300 of the present invention. In this
illustration, wall block 300 is used to form a wall having a front
surface and a rear surface and has been manufactured to have two
lugs 320. Generally, when constructing a wall, a trench is
excavated to a pre-selected depth and lined with a level base of
granular material such as crushed stone. A base layer is then
placed and leveled onto the crushed stone. The blocks are placed
side to side with front face 304 facing outward and the bottom
surface 303 facing downward. Once the base layer is laid, the
second layer is built using the rear lugs to connect the upper
block to the lower block course. It should be noted that when the
block is used in constructing a gravity wall the weight of the
blocks and the lugs are sufficient for connection without the use
of the pinning system. When a geogrid layer is intended to be built
into the wall structure, pins 50 are placed into pin holes 318 of
the top surface of the blocks and geogrid soil reinforcement
material G is then hooked over pins 50 and pulled taut (towards the
backfill embankment). The heads 52 of pins 50 are then received in
the pin receiving channels 330 in the bottom surface of the upper
adjacent course of blocks. It should be noted that the pinning
system may be used without the geogrid as desired. Lugs 320 abut
the rear face 305 of the blocks in the lower course as shown in
cross-section in FIG. 16. The abutment produces a shear connection
and prevents displacement and slippage of the blocks due to forces
created by the retained earth behind the structure being
constructed. Successive courses are then likewise laid one on top
of the other until a desired height is achieved. When the desired
height is achieved a cap or finish layer 30, shown in partial view
at the top of the wall, may be added. It should further be noted
that in some applications where the wall design is more elaborate
or the height of the wall is such that the structure needs further
stabilization, vertical reinforcing members such as rebar may be
threaded through vertical open cores (columnar cavities) created by
the cores of blocks as they are stacked one upon the other. It
should further be noted that the wall may be constructed with two
or more sizes of block as desired for a more random appearance of
the wall aesthetic depending upon the application.
[0062] FIG. 17 illustrates the wall 550 built with geogrid G as
known and used in the art. The wall is built from base course to
top course as described above using blocks 100. When geogrid G is
used with a course of blocks it is placed upon the top face 102 of
block 100. Pin 50 is then inserted through the geogrid and into pin
hole 118. The head of the pin securing the geogrid to block 100 is
received in the pin receiving channel 130 of the upper course of
block 100a. The lug may be removed if desired when incorporating
geogrid into the structure. Removal of the lug may help to avoid
possible tearing of the geogrid material.
[0063] FIGS. 18 and 19 illustrate perspective views of retaining
wall 600 made from the multiple block system of this invention. In
this illustration, wall blocks 100, 200 and 300, each having a
different front face length, are used to form a wall having a front
surface and a rear surface. The differing sizes of blocks used in
the construction of the wall contribute to the random, natural
appearance of the wall. A base layer is placed and leveled onto a
crushed stone base. The blocks are placed side to side with front
faces 104, 204 and 304 facing outward and the bottom surfaces 103,
203, and 303 facing downward. When constructing a wall without
geogrid soil reinforcement material a base layer of blocks is laid
and an upper adjacent course is then laid on top of the base layer
with lugs 120, 220, and 320 abutting the rear faces of the blocks
in the lower course. The abutment prevents displacement and
slippage of the blocks due to the forces created by the retained
earth the constructed structure holds back. Successive courses are
then likewise laid one on top of the other until a desired height
is achieved. When the desired height is achieved a cap or finish
layer 30, shown in partial view at the top of the wall, may be
added.
[0064] When constructing a wall with geogrid reinforcement material
for walls which need geogrid to add structure to the mechanically
stabilized earth, a base layer of blocks is laid and pins 50 are
placed into pin hole of top surface of the blocks. Geogrid of a
specific design is then placed over the pins or the geogrid is
placed on the blocks first, and then the pins are put into the open
pin holes on the top surface of the block to connect the geogrid to
the blocks. The heads 52 of pins 50 are then received in the pin
receiving channels in the bottom surfaces of the upper adjacent
course of blocks with lugs 120, 220, and 320 abutting the rear
faces of the blocks in the lower course and aligning the blocks in
the upper course.
[0065] FIG. 20 illustrates a perspective view of retaining wall 650
made from the multiple block system of this invention. In this
illustration, wall blocks 100, 200, and 300, each having a
different length, are used to form a wall having a front surface
and a rear surface. The converging, non-parallel side walls of
blocks 100, 200, and 300 allow for a radial curvature of the wall
to be achieved in the structure being constructed. The lugs on the
back lower surface of blocks 100, 200 and 300 allow for an
alignment and setback system of the present invention to follow the
radial curvature of the structure as well as giving greater
variability. Optionally, geogrid can be added to the structure by
using the pinning system as described above. It should be noted
that the converging, non-parallel side walls of the blocks of the
present invention allow for the structure being constructed to have
many different shapes and contours such as linear, curvilinear,
serpentine, L-shaped, etc.
[0066] FIGS. 21 and 22 illustrate wall 700 built with right hand
and left hand corner blocks 400(r), 400(l) and wall blocks 100. A
trench is excavated to a pre-selected depth and lined with a level
base of granular material such as crushed stone. A base layer is
then placed and leveled onto the crushed stone. The blocks of the
straight section of the wall are placed end to end with a front
face projecting outwardly. The corner of the base layer is formed
by the placement of right handed or left handed corner block of the
present invention at the desired location for the corner. Base
layer 710 is shown with a right handed corner block 400(r) which
offsets the base layer of straight wall portion 700b by the length
of front face 404 of corner block 400(r), the base layer of
straight wall portion 700a is thus offset by the length of side
face 412 of corner block 400(r). Pins 50 may be placed into pin
holes 418 of corner block 400(r) and additionally into the pin
holes of blocks 100 of the base layer. These act as shear
connectors for the corner block and points at which geogrid can be
introduced for structural purposes.
[0067] Once the base layer is laid, first layer 720 of blocks is
placed on the base layer and pin receiving channels 430 and 440 of
corner block 400(l) and pin receiving channels of blocks 100 of the
first course capture the heads of pins 50 in base layer 710. This
pin alignment system is thus compatible with both the corner block
and the wall block thus adding to the overall stability and
structural integrity of the structure being built. First layer 720
is shown with left handed corner block 400(l) which offsets the
base layer of straight wall portion 700a by the length of front
face 404 of corner block 400(l), the first layer of straight wall
portion 700b is thus offset by the length of side face 412 of
corner block 400(l). In this embodiment the placement of blocks is
vertically offset in adjacent courses in a running bond pattern by
the use of the alternating courses of the left and right handed
corner blocks 400. It is to be understood that a wall could be
formed using only left handed corner blocks or right handed corner
blocks but the wall would have a stacked bond configuration.
[0068] Subsequent layers of blocks can then be placed one on top of
the next with the pin connection system while alternating the left
and right handed corner blocks of adjacent layers of the wall until
the desired height is reached. The specific dimensions of the
corner block ensure that seams between blocks of one course will
not be directly vertically adjacent to the same seam between blocks
in the adjacent course. The alignment of cores 417 of the
alternating courses of left and right handed corner blocks 400
create a vertical columnar cavity at the corner of wall 700. Steel,
fiberglass or other suitable rebar can be thread through the
columnar cavity and may additionally be filled with concrete grout
for additional stability. It should further be noted that
reinforcement may be added to the columnar cavities created by the
openings of cores 114 of blocks 100 as well. It should be
additionally noted that the columnar cavities may be filled with a
stabilizing material such as sand, gravel, sheer resistant fill
(i.e. crushed stone), concrete, cement or the like with or without
the need for rebar depending upon the application. Optionally,
construction adhesive may be used to further lock blocks and/or
courses together with or without the use of stabilizing materials.
A geogrid as known and used in the art is may also be used in the
construction of wall 700. Once the desired height is reached a
capping layer may be added.
[0069] An alternative embodiment of block 100 is shown in FIGS. 23
and 24. Block 800 has parallel top face 802 and bottom face 803,
front face 804, rear face 805 and first and second side walls 806
and 807. Front face 804 and rear face 805 each extend from top face
802 to bottom face 803. Side walls 806 and 807 extend from top face
802 to bottom face 803, and have a compound shape converging back
from front face 804 toward back portion 809 which extends outward
from the converging angle of the side walls 806 and 807. Front face
804 may be of a compound shape. Block 800 comprises body portion
808, back portion 809 and neck portions 810 which connect body
portion 808 to back portion 809. Front face 804 forms part of body
portion 808, while rear face 805 forms part of back portion 809.
The body, back and neck portions 808, 809, and 810 each extend
between top and bottom faces 802 and 803 and between first and
second side walls 806 and 807. Opening or core 814 may extend
through neck portion 810 from top surface 802 to bottom face 803,
or may only extend part of the way through block 800 (for example,
open to top surface 802 but closed at bottom surface 803).
[0070] A set of pin holes 818 are located in back portion 809 and
extend from top face 802 to bottom face 803, i.e., opening onto
both top and bottom surfaces. Bottom surface 803 has pin receiving
channel 830 located in body portion 808, adjacent to back portion
809. Block 800 has three lugs 820 located on back portion 809 which
extend from the rear face 805 downward past the bottom face 803 of
the block.
[0071] An alternative embodiment of the block is shown in FIGS. 25
and 26. Block 900 has parallel top face 902 and bottom face 903,
front face 904, rear face 905 and first and second side walls 906
and 907. Front face 904 and rear face 905 each extend from top face
902 to bottom face 903. Side walls 906 and 907 extend from top face
902 to bottom face 903, and have a compound shape. Block 900
comprises body portion 908, back portion 909 and neck portions 910
which connect body portion 908 to back portion 909. Front face 904
forms part of body portion 908, while rear face 905 forms part of
back portion 909. The body, back and neck portions 908, 909, and
910 each extend between top and bottom faces 902 and 903 and
between first and second side walls 906 and 907. Opening or core
914 may extend through neck portion 910 from top surface 902 to
bottom face 903, or may only extend part of the way through block
900 (for example, open to top surface 902 but closed at bottom
surface 903).
[0072] A set of pin holes 918 are located in neck portion 910 and
extend from top face 902 to bottom face 903, i.e., opening onto
both top and bottom surfaces. Pin hole depressions 919 located on
the bottom face of the neck portion 910 are formed from a pin hole
forming member or bridge (not shown) which is mounted to a side
wall or liner of a mold cavity. Bottom surface 903 has pin
receiving channel 930 located in neck portion 910, adjacent to body
portion 908. Block 900 has three lugs 920 located on back portion
909 which extend from the rear face 905 downward past the bottom
face 903 of the block.
[0073] An alternative embodiment of the block is shown in FIG. 27.
Block 900a is similar to block 900. Block 900a has parallel top
face 902a and bottom face 903a, front face 904a, rear face 905a and
first and second side walls 906a and 907a. Front face 904a and rear
face 905a each extend from top face 902a to bottom face 903a. Side
walls 906a and 907a extend from top face 902a to bottom face 903a,
and have a compound shape. Block 900a comprises body portion 908a,
back portion 909a and neck portions 910a which connect body portion
908a to back portion 909a. Front face 904a forms part of body
portion 908a, while rear face 905a forms part of back portion 909a.
The body, back and neck portions 908a, 909a, and 910a each extend
between top and bottom faces 902a and 903a and between first and
second side walls 906a and 907a. Opening or core 914a may extend
through neck portion 910a from top surface 902a to bottom face
903a, or may only extend part of the way through block 900a (for
example, open to top surface 902a but closed at bottom surface
903a).
[0074] A set of pin holes 918a are located in neck portion 910a and
extend from top face 902a to bottom face 903a, i.e., opening onto
both top and bottom surfaces. Pin hole depressions 919a located on
the bottom face of the neck portion 910a are formed from a pin hole
forming member or bridge (not shown) which is mounted to a side
wall or liner of a mold cavity. Bottom surface 903a has pin
receiving channel 930a located in neck portion 910a, adjacent to
body portion 908a. Block 900a has three lugs 920a located on back
portion 909a which extend from the rear face 905a downward past the
bottom face 903a of the block.
[0075] FIG. 28 illustrates a portion of a wall 850 built with
blocks 800 of the present invention. The wall is built from base
course to top course as described above.
[0076] FIG. 29 illustrates a portion of a concave wall 950 built
with blocks 900 of the present invention. The wall is built from
base course to top course as described above.
[0077] FIG. 30 illustrates a portion of a convex wall 960 built
with blocks 900 of the present invention. The wall is built from
base course to top course as described above.
[0078] 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
appended claims, which follow. In particular, it is contemplated by
the inventor 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.
* * * * *