U.S. patent application number 13/861539 was filed with the patent office on 2013-08-29 for building block, system and method.
This patent application is currently assigned to Stone Strong LLC. The applicant listed for this patent is Stone Strong LLC. Invention is credited to Larry J. Ebert, Michael Furlong, John J. Gran, Daniel Thiele.
Application Number | 20130219808 13/861539 |
Document ID | / |
Family ID | 47291951 |
Filed Date | 2013-08-29 |
United States Patent
Application |
20130219808 |
Kind Code |
A1 |
Gran; John J. ; et
al. |
August 29, 2013 |
BUILDING BLOCK, SYSTEM AND METHOD
Abstract
A block system includes a main block that has the lift and
alignment devices positioned to overlie a longitudinal axis that
intersects a center of gravity of the main block, and has a defined
distance from the lift and alignment devices to a front surface of
the main block. The block system further includes extended blocks
that each has the lift and alignment devices positioned not to
overlie a longitudinal axis that intersects a center of gravity of
the extended block, but has the same defined distance from the lift
and alignment devices to a front face of the extended block that
exists on the main block. The recessed portions of the block may be
larger than the lift and alignment devices, thereby allowing the
blocks to be stacked in either a vertical wall or in a setback
wall.
Inventors: |
Gran; John J.; (Lincoln,
NE) ; Thiele; Daniel; (Omaha, NE) ; Ebert;
Larry J.; (Apple Valley, MN) ; Furlong; Michael;
(Cambridge, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Stone Strong LLC; |
|
|
US |
|
|
Assignee: |
Stone Strong LLC
Lincoln
NE
|
Family ID: |
47291951 |
Appl. No.: |
13/861539 |
Filed: |
April 12, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13158411 |
Jun 11, 2011 |
|
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13861539 |
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Current U.S.
Class: |
52/125.2 |
Current CPC
Class: |
E04G 21/142 20130101;
E04C 1/395 20130101; E04G 21/147 20130101 |
Class at
Publication: |
52/125.2 |
International
Class: |
E04G 21/14 20060101
E04G021/14 |
Claims
1. A wall system for building a wall comprising: (A) a main block
comprising: a first back surface; first and second side surfaces
coupled to the back surface; a first top surface coupled to the
back surface and to the first and second side surfaces, wherein the
first top surface includes a first lift and alignment device for
lifting the main block when the main block is being placed, the
first lift and alignment device aligning a subsequently-placed
block with respect to the main block, the first lift and alignment
device overlying a first longitudinal axis that intersects a first
center of gravity for the main block, resulting in the first lift
and alignment device being a predetermined distance from a first
front face of the main block; and a first bottom surface coupled to
the first back surface and to the first and second side surfaces,
the bottom surface including at least one recess positioned to
receive the lift and alignment device of a previously-placed block;
(B) an extended block comprising; a second back surface; third and
fourth side surfaces coupled to the second back surface; a second
top surface coupled to the second back surface and to the third and
fourth side surfaces, wherein the second top surface includes a
second lift and alignment device for lifting the extended block
when the extended block is being placed, the second lift and
alignment device aligning a subsequently-placed block with respect
to the extended block, the second lift and alignment device being
the same predetermined distance from a second front surface of the
extended block as the distance from the first lift and alignment
device to the first front surface of the main block, wherein the
second lift and alignment device does not overlie a second
longitudinal axis that intersects a second center gravity for the
extended block.
2. The wall system of claim 1 further comprising the main block
having the first back surface and a first front surface that are
both finished surfaces of the block that resemble stone.
3. The wall system of claim 1 wherein the main block and the
extended block both include at least one void extending from the
first top surface to the first bottom surface.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] This invention generally relates to construction materials
and techniques, and more specifically relates to a building block
wall system and method that may be used to construct a wall or
support.
[0003] 2. Background Art
[0004] Building blocks have been used for centuries to construct
homes, office buildings, churches, and many other structures. Early
building blocks were hewn from stone into appropriate shapes that
were assembled together, typically using mortar, to form a wall. In
modern times, various types of concrete blocks have been developed,
which are typically formed by pouring a cement-based concrete
mixture into a form and allowing the concrete to cure. This type of
concrete block is strong and makes for a sturdy wall, but
installing a traditional concrete block requires a skilled mason
that must manually lift each block, and set each block using mortar
to secure the blocks in place. This process is very
labor-intensive.
[0005] One application for concrete blocks is the construction of
retaining walls. Retaining walls are required when there is a body
of earth that needs to be held in place. While several different
block designs have been used in the art, most of these are
relatively small blocks that a construction worker must manually
lift and put in place. Most require mortar and a considerable
amount of labor to install. U.S. Pat. No. 6,796,098, which issued
on Sep. 28, 2004, and U.S. Pat. No. 7,703,304, which issued on Jul.
11, 2006, disclose building blocks and a building block system that
greatly simplifies construction of a wall using the blocks. These
two patents are owned by Stone Strong LLC of Lincoln, Nebr., and
are incorporated herein by reference. The blocks have a relatively
large, finished surface. The blocks include one or more lift and
alignment devices in the block that allow the block to be lifted
using a suitable lifting apparatus, such as a crane, forklift,
backhoe, etc. The blocks include one or more recessed portions in
the bottom surface of the block positioned to receive the
protruding lift and alignment device of a previously-laid block
underneath, thereby helping to align the block with the
previously-laid block. Some embodiments of the blocks include one
or more voids that extend from the top surface to the bottom
surface of the block, and that align with each other when the
blocks are stacked into a wall, thereby allowing fill material to
be placed in the voids to strengthen the wall. A wall system
includes various different blocks that may be used to build a wall,
including corner blocks that allow abruptly changing the direction
of the wall.
DISCLOSURE OF INVENTION
[0006] According to the preferred embodiments, a system of blocks
has a finished surface that provides an attractive appearance. The
blocks are relatively large in size, allowing the quick
construction of a wall, such as a retaining wall, using the blocks.
The blocks include one or more lift and alignment devices in the
block that allow the block to be lifted using a suitable lifting
apparatus, such as a crane, forklift, backhoe, etc. The blocks
include one or more recessed portions in the bottom surface of the
block positioned to receive the protruding lift and alignment
device of a previously-laid block underneath, thereby helping to
align the block with the previously-laid block. The block system
includes a main block that has the lift and alignment devices
positioned to overlie a longitudinal axis that intersects a center
of gravity of the main block, and has a defined distance from the
lift and alignment devices to a front surface of the main block.
The block system further includes extended blocks that each has the
lift and alignment devices positioned not to overlie a longitudinal
axis that intersects a center of gravity of the extended block, but
has the same defined distance from the lift and alignment devices
to a front surface of the extended block that exists on the main
block. The recessed portions of the blocks may be larger than the
lift and alignment devices, thereby allowing the blocks to be
stacked in either a vertical wall or in a setback wall. A block in
the block system may include a mass extender on a back of the block
to improve the load-bearing capability of the block.
[0007] A method for making a block includes the steps of
determining a center of gravity for the block, determining a
longitudinal axis that intersects the center of gravity for the
block, and positioning one or more lift and alignment rings
overlying the longitudinal axis.
[0008] The foregoing and other features and advantages of the
invention will be apparent from the following more particular
description of preferred embodiments of the invention, as
illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0009] The preferred embodiments of the present invention will
hereinafter be described in conjunction with the appended drawings,
where like designations denote like elements, and:
[0010] FIG. 1 is a top view of a block that has lift and alignment
rings overlying a longitudinal axis that intersects a center of
gravity for the block;
[0011] FIG. 2 is a side view of the block of FIG. 1;
[0012] FIG. 3 is a top view of the block of FIG. 1 showing a
reinforcing structure that adds strength to the block;
[0013] FIG. 4 is cross-sectional view of the block in FIG. 3 taken
along the lines 4-4 that shows the connection of lift and alignment
ring 170 to the reinforcing structure;
[0014] FIG. 5 is a flow diagram of a method for making a block;
[0015] FIG. 6 is a flow diagram of additional steps in the method
for making a block;
[0016] FIG. 7 is a top view of a first extended block;
[0017] FIG. 8 is a top view of a second extended block;
[0018] FIG. 9 is a top view of a third extended block that includes
a mass extender on its back surface to increase the load bearing
capability of the block;
[0019] FIG. 10 is a side view of one alternative to the main block
in FIG. 1 that includes a recess on the bottom surface that is
substantially larger than the lift and alignment rings, thereby
allowing the block to be stacked in either a vertical wall
configuration or in a setback wall configuration;
[0020] FIG. 11 is a side view of one alternative to the extended
block in FIG. 7 that includes a recess on the bottom surface that
is substantially larger than the lift and alignment rings, thereby
allowing the block to be stacked in either a vertical wall
configuration or in a setback wall configuration;
[0021] FIG. 12 is a side view of one alternative to the extended
block in FIG. 8 that includes a recess on the bottom surface that
is substantially larger than the lift and alignment rings, thereby
allowing the block to be stacked in either a vertical wall
configuration or in a setback wall configuration;
[0022] FIG. 13 is a side diagram of a wall built with four courses
of the block 100 in FIG. 1;
[0023] FIG. 14 is a side diagram of a wall built with four courses
of the block 100 in FIG. 1 atop a course of extended blocks 700 in
FIG. 7;
[0024] FIG. 15 is a side diagram of a wall built with four courses
of the block 100 in FIG. 1, a course of extended blocks 700 in FIG.
7, and a course of extended blocks 800 in FIG. 8;
[0025] FIG. 16 is a side diagram of a vertical wall built with four
courses of the block 1000 in FIG. 10, a course of extended blocks
1100 in FIG. 11, and a course of extended blocks 1200 in FIG. 12,
showing how the larger recesses in the bottom surfaces of the block
allow building a vertical wall; and
[0026] FIG. 17 is a side diagram of a setback wall built with the
same blocks in FIG. 16.
BEST MODE FOR CARRYING OUT THE INVENTION
[0027] Referring now to FIGS. 1 and 2, a building block 100
includes a front surface 110, a left side surface 120, a right side
surface 130, and a back surface 140, all coupled together via a top
surface 150 and a bottom surface 160. Any or all of the front
surface 110, the side surfaces 120 and 130, and the back surface
140 could have a finished, decorative surface that resembles stone
or provides other desired appearance.
[0028] Referring to FIG. 2, for the specific configuration shown in
the drawings, the front surface 110 has an uneven surface comprised
of a lower finished surface 214 and an offset upper finished
surface 212. The offset upper finished surface 212 gives the
appearance of a separate course of stone, and enhances the look of
a finished wall that is built using the block 100. The preferred
embodiments, however, expressly extend to a block that has an even
finished surface and that is placed in a wall to provide a
straight, vertical wall surface.
[0029] Block 100 preferably includes one or more voids that extend
from the top surface to the bottom surface of the block. Examples
of suitable voids are shown in FIG. 1 to include a fully enclosed
void 180 and two partially enclosed voids 182 and 184. When blocks
100 are laid next to each other, partially enclosed voids 182 and
184 of adjacent blocks combine to form a void similar in size to
void 180. These voids are designed to align with voids of other
blocks when the blocks are stacked to form a wall. The voids may be
filled with an appropriate filler material, such as recycled
concrete, gravel, concrete, etc. Filling the voids with an
appropriate filler material increases the shear strength of a wall
built using the block 100. The preferred embodiments also extend to
a block 100 that is solid, and thus has no voids.
[0030] Block 100 preferably includes one or more devices that allow
lifting the block 100. For example, block 100 in the figures
includes two semicircular lift and alignment rings 170 (best shown
in FIG. 2) that protrude from the top surface 150 of the block that
allow the block to be lifted using a suitable lifting apparatus,
such as a crane, forklift, backhoe, etc. Block 100 preferably
includes one or more recesses or alignment channels 162 (FIG. 2) in
the bottom surface 160 of the block that helps align the block 100
with a previously-laid block underneath. The alignment channel 162
is recessed into bottom surface 160, as shown in FIG. 2. In the
case where the block does not have one or more voids, then
alignment channel 162 would preferably run the entire width of
block 100. In the most preferred implementation, the radius of the
outside of the lift and alignment rings 170 is preferably 8.75
inches (22.2 cm), and the alignment channel 162 is configured to
receive a lift and alignment ring with a radius of 9.5 inches (24.1
cm). The lift and alignment rings 170 may be made of any suitable
material that provides sufficient strength to allow lifting the
block 100 using the lift and alignment rings 170. In the preferred
embodiments, lift and alignment rings 170 are made of No. 6 rebar,
which may be coated with a non-corrosive coating, such as
fiberglass resin. No. 6 rebar refers to a specific rebar diameter;
however, the preferred embodiments include any suitable rebar
diameter and any suitable coating. In addition, lift and alignment
rings 170 could be made of smooth metal bar, and may be made of
stainless steel or other non-corrosive material which could be used
in a corrosive environment, such as on an ocean shoreline.
Additionally, the preferred embodiments include any suitable radius
of the lift and alignment rings 170 and any suitable geometric
configuration for channel 162 to receive the lift and alignment
rings 170.
[0031] The lift and alignment rings 170 are preferably placed
overlying a longitudinal axis B that intersects the center of
gravity A for the block 100. The center of gravity A may be
determined using any suitable means, including computer modeling,
calculations, or empirical tests. In the most preferred
implementation, the center of the semi-circular lift rings 170 are
placed directly over the axis B that intersects the center of
gravity, as shown in FIG. 2. Note, however, the terms "underlying"
and "underlies" as used in the disclosure and claims herein mean
the lift and alignment ring 170 shown in FIG. 2 has any portion
that is over the axis B when the block is positioned with its top
surface 150 up, as shown by the dotted lines in FIG. 2 extending
downward from the lift and alignment ring 170 in FIG. 2. By
positioning the lift and alignment rings 170 to overlie the axis B
that intersects the center of gravity, the block will be more level
when lifted using a crane or other suitable equipment.
[0032] The semicircular shape of protruding portion of the lift and
alignment rings 170 shown in FIG. 2 and the shape of the alignment
channels 162 provide a mechanism for easily aligning a block on top
of a previously-laid block. The block 100 of FIG. 1 is preferably
heavy enough that it will typically be set in place using suitable
equipment, such as a crane. The lift and alignment rings 170
provide easy loops for attaching hooks to lift the block 100. As
the block is lowered into place on previously-set blocks, the shape
of the alignment channel 162 has an aligning effect on the block as
it is lowered onto the lift and alignment rings 170 of one or more
previously-laid blocks. If the block is slightly too far to the
front or back, the weight of the block will cause the block to
shift as it is lowered until the lift and alignment rings 170 lie
within the alignment channels 162. This is the how the lift and
alignment rings 170 perform their aligning function. The lift and
alignment rings thus provide a dual function. They provide lift
hooks that allow lifting the block and placing it in a wall. They
also provide an alignment mechanism to align the alignment channel
of a subsequently-placed block with one or more lift and alignment
devices of one or more blocks that have been previously placed.
This dual function for lift and alignment rings 170 provides
significant advantages over other building blocks.
[0033] While lift and alignment rings 170 are shown herein in a
semicircle shape, and alignment channel is shown as a channel with
beveled sides, the preferred embodiments expressly extend to any
and all suitable geometries for lift and alignment rings 170 and
alignment channel 162. For example, a semicircular lift and
alignment ring 170 could be used with a rectangular or square
alignment channel 162. In the alternative, both lift and alignment
ring 170 and alignment channel 162 may be triangular in shape. Any
suitable geometric shape for the lift and alignment ring 170 may be
used with any compatible geometric shape for the alignment channel
within the scope of the preferred embodiments.
[0034] Referring now to FIG. 3, the block 100 preferably includes a
reinforcing structure within the block that provides structural
strength to the block. A suitable reinforcing structure 300 is
shown in FIG. 3 to include a front piece 310 that runs the width of
the front surface 110, a back piece 320 that runs the width of the
back surface 140, a left side piece 330, and a right side piece
340. Each of these pieces preferably provides a grid-like structure
that reinforces the concrete in the block. In the preferred
embodiments, D4 metal wire mesh, grade 80 with a spacing of 4
inches (10.2 cm) is used. Each piece is secured to the adjacent
other pieces using any suitable technique, such as tying with wire,
welding, etc. In the preferred embodiments, the different pieces of
the reinforcing structure 610 are attached to each other using wire
ties that are tied around both adjacent pieces. Of course, the
preferred embodiments extend to any suitable reinforcing structure
that adds structural strength to the block, regardless of its
composition or configuration. For example, rebar may be used
instead of wire mesh. The reinforcing structure 610 provides
structural reinforcement that allows the block 100 to be used in
tall walls or in load-bearing applications, if required. In some
applications, the reinforcing structure 300 may be omitted
altogether.
[0035] For the preferred implementation that uses 4 inch (10.2 cm)
metal wire mesh, a cross-sectional side view taken along the line
4-4 in FIG. 3 is shown in FIG. 4. Note that the block 100 is shown
in phantom in FIG. 4 to more clearly show how the lift and
alignment ring 170 is attached to the left side piece 330 of the
reinforcing structure 300. One specific way to attach the lift and
alignment ring 170 to the left side piece 330 of the reinforcing
structure 300 is to wire the two together at the points indicated
with small circles in FIG. 4 with wire ties. Of course, welding or
any type of fastener could also be used. By attaching the lift and
alignment rings 170 to the reinforcing structure 300 of the block,
the lift and alignment rings 170 will not pull out of the block 100
under the weight of lifting the block 100. Note the lift and
alignment rings 170 are positioned in FIG. 4 overlying the axis B
that intersects the center of gravity A of the block 100. The size
and properties of the reinforcing structure 300 and lift and
alignment rings 170 may vary according to the engineering
requirements for a wall constructed using the block 100. For
applications that do not use a reinforcing structure, the lift and
alignment rings 170 will be embedded in the concrete of the block
without being attached to a reinforcing structure.
[0036] Block 100 is preferably comprised of a mixture of sand,
gravel, cement, and water that is placed around the reinforcing
structure 300 and the attached lift and alignment rings 170 to form
a block. The cement is preferably Portland cement, type 1, ASTM
designation C150 or similar. The resulting mix is preferably
denoted L4000, which represents a mixture of sand, gravel, cement,
and water in proportions that results in a finished product capable
of bearing approximately 4000 pounds per square inch (280 kilograms
per square centimeter). L4000 mix preferably includes entrained
air, which helps the block withstand freeze and thaw cycles. Note
that L4000 is a common expression in the concrete art that denotes
specific proportions of the ingredients. While L4000 is the
preferred block material, the preferred embodiments also extend to
any other suitable block material.
[0037] Referring now to FIG. 5, a method 500 for making a block
begins by determining the center of gravity A for the block (step
510). A longitudinal axis B is then determined that intersects the
center of gravity A (step 520). The lift and alignment rings are
then positioned to overlie the longitudinal axis B (step 530). By
positioning the lift and alignment rings to overlie the
longitudinal axis B, the block will be more level when lifting the
block for installation than it would otherwise be.
[0038] FIG. 6 shows a method 600 that includes additional steps
that could also be performed in making the block. A reinforcing
structure is installed in a form (step 610). One suitable example
of such a reinforcing structure is reinforcing structure 300 shown
in FIG. 3. The lift and alignment rings are then positioned to
overlie the longitudinal axis B by attaching one end of the lift
and alignment rings to the reinforcing structure (step 620).
Concrete is then poured into the form so the reinforcing structure
is substantially embedded in the concrete, the end of the lift and
alignment ring(s) attached to the reinforcing structure is embedded
in the concrete, and the opposite end of the life and alignment
ring(s) extends above the top surface of the block (step 640). The
result is lift and alignment rings that are firmly embedded in the
concrete in a position that overlies the longitudinal axis B that
intersects the center of gravity A, which makes installation of the
block much easier.
[0039] The block illustrated in FIGS. 1-4 is called a "main block"
herein. In addition to the main block 100, three different types of
extended blocks are also included in the block system disclosed
herein. These are shown as block 700 in FIG. 7, block 800 in FIG.
8, and block 900 in FIG. 9. These blocks have a similar structure
when compared to the main block, but are much wider than the main
block. Extended blocks provide greater strength for a wall. For
example, in the blocks currently being manufactured by Stone Strong
LLC of Lincoln, Nebr., the main block is 36 inches (91.4 cm) high
by 96 inches (243.8 cm) long by 44 inches (111.8 cm) wide. The
first extended block 700 shown in FIG. 7 has a height and length
the same as the main block 100 in FIG. 1, and has a width from
front surface 110 to the back surface 140 of 62 inches (157.5 cm).
The second extended block 800 shown in FIG. 8 has a height and
length the same as the main block 100 in FIG. 1, and has a width
from front surface 110 to the back surface 140 of 86 inches (218.4
cm). The third extended block 900 shown in FIG. 9 has a height and
length the same as the main block 100 in FIG. 1, and has a width
from front surface 110 to the back surface 140 of 56 inches (142.2
cm). Note that block 900 in FIG. 9 includes a relatively thick
portion 910 known as a "mass extender", which improves the
load-bearing capability of the block.
[0040] Note the lift and alignment rings 170 in the extended block
700 in FIG. 7 do not overlie the axis B that intersects the center
of gravity A for the block 700. Likewise, the lift and alignment
rings 170 in the extended block 800 in FIG. 8 do not overlie the
axis B that intersects the center of gravity A for the block 800.
Similarly, the lift and alignment rings 170 in the extended block
900 in FIG. 9 do not overlie the axis B that intersects the center
of gravity A for the block 900. Instead, the lift and alignment
rings are positioned along a line C that is a fixed distance D from
the front surface 110 for each of blocks 700, 800 and 900. Note
this distance is the same as distance D shown in FIG. 1 for the
main block 100 in FIG. 1. By making the distance from the front
surface to the lift and alignment rings the same for all blocks
100, 700, 800 and 900, any block can be stacked atop any other
block. Thus, one or more courses of the main block 100 could be
placed atop one or more courses of any of the extended blocks 700,
800 or 900, or atop any suitable combination of extended blocks
700, 800 and 900, or vice versa. In addition, it is within the
scope of the disclosure and claims herein to build a wall
completely of one or more courses of extended blocks 700, 800 or
900 without using any main blocks 100. In one specific
implementation, one or more courses of the deepest extended block
800 could be placed, followed by one or more courses of the
extended block 700, followed by one or more courses of main blocks
100.
[0041] FIGS. 10, 11 and 12 show variations 1000, 1100 and 1200 of
the main block 100, extended block 700, and extended block 800,
respectively. Each of these blocks 1000, 1100 and 1200 includes a
recess in the bottom surface that has a width F that is
substantially wider than a width G of the lift and alignment ring
170 shown in FIG. 10. In the most preferred implementation, the
width F of the recess is at least as wide as the sum of the width G
of the lift and alignment ring plus the setback S from the front
edge of the recess to the front edge of the lift and alignment
ring. This allows each block to be stacked in either a vertical
wall configuration or a setback wall configuration. Note also the
front edge of the recess is a fixed distance H from the front
surface of each block. In addition, the front surfaces of blocks
1000, 1100 and 1200 shown in FIGS. 10-12 do not have an upper half
that is offset from the lower half as shown in FIG. 2, but have
upper halves of the front surfaces that are aligned with the lower
half of the front surfaces. The combination of the front surfaces
not having an offset coupled with a larger recess allows the blocks
to be stacked in either a vertical wall configuration or in a
setback wall configuration.
[0042] FIG. 13 illustrates a wall 1300 built with four courses of
block 100 shown in FIG. 1, denoted 100A, 100B, 100C and 100D. The
course 100A is placed first, followed by course 100B, followed by
course 100C, followed by course 100D. FIG. 14 shows a wall 1400
built by placing a course 700A of extended blocks 700 in FIG. 7,
followed by course 100A of main blocks, followed by course 100B of
main blocks, followed by course 100C of main blocks, followed by
course 100D of main blocks. FIG. 15 shows a wall 1500 built by
placing a course 800A of extended blocks 800 in FIG. 8, followed by
course 700A of extended blocks 700 in FIG. 7, followed by course
100A of main blocks, followed by course 100B of main blocks,
followed by course 100C of main blocks, followed by course 100D of
main blocks. Of course, other variations are possible, which are
within the scope of the disclosure and claims herein.
[0043] Referring to FIG. 16, a vertical wall may be built using the
blocks 1000, 1100 and 1200 shown in FIGS. 10-12, respectively. The
vertical wall is possible due to two variations in the design of
the block, namely: 1) a front surface that has a top half that is
not offset from the bottom half; and 2) a recess that is at least
the width of the lift and alignment rings plus the distance from a
front edge of the recess to the front surface of the block, thereby
allowing greater variation in how the block is placed atop a
previously-placed block. The wall 1600 in FIG. 16 is made by
placing a course 1200A of extended blocks 1200 shown in FIG. 12.
Next, a course 1100A of extended blocks 1100 shown in FIG. 11 is
placed, followed by four courses 1000A, 1000B, 1000C and 1000D of
main blocks 1000 shown in FIG. 10. For the specific configuration
shown in FIGS. 10-12 and 16, a vertical wall is achieved by placing
a block atop an existing block so the lift ring is in proximity to
the rear wall of the recess, as shown in FIG. 16. Having the recess
substantially larger than the lift and alignment ring allows the
same blocks to also be built into a setback wall configuration, as
shown by wall 1700 in FIG. 17. Note the blocks used in wall 1700
are identical to the blocks used in wall 1600 in FIG. 16. The
difference is how these blocks are placed. For the specific
configuration shown in FIGS. 10-12 and 17, a setback wall is
achieved by placing a block atop an existing block so the lift ring
is in proximity to the front wall of the recess, as shown in FIG.
17. By providing a recess that is larger than the lift and
alignment rings, the same blocks may be stacked to form a vertical
wall 1600 shown in FIG. 16 or a setback wall 1700 shown in FIG.
17.
[0044] While the specific examples in FIGS. 10-12 and 16-17 show a
recess that has a front wall that defines a setback wall
configuration and a rear wall that defines a vertical wall
configuration, the width of the recess could be substantially
larger than shown in these figures. When the recess is
substantially larger than the lift and alignment ring, the lift and
alignment ring may not be in proximity to the front wall or rear
wall of the recess when the block is placed atop a
previously-placed block. When this is the case, the precise
alignment of the blocks may be achieved using other known means
such as levels, tape measures and/or plumb bobs. Note, however, the
recess still performs a coarse aligning function as the block is
placed by requiring the lift ring be within the recess before the
block can be placed in its final, desired position.
[0045] A wall system that includes the blocks disclosed herein
includes main blocks such as 100 shown in FIG. 1 that have lift and
alignment rings that overlie a longitudinal axis that intersects
the center of gravity of the block, and one or more other blocks
such as 700 in FIG. 7, 800 in FIGS. 8, and 900 in FIG. 9 that have
lift and alignment rings that do not overlie a longitudinal axis
that intersects the center of gravity of the block, but instead
have lift rings that are the same fixed distance from the front
surface of the block as in the main block. For the blocks such as
700, 800 and 900 that have lift and alignment rings that do not
overlie a longitudinal axis that intersects the center of gravity
of the block, these block may include one or more additional lift
rings to help keep the block level when the block is placed. For
example, block 800 in FIG. 8 includes a third lift ring 800
extending from the back surface. When placing block 800, hooks
could be placed on the two front lift rings 170 and on the rear
lift ring 810 to keep the block level when putting the block in
place. Note the third lift ring could also extend from the top
surface of the block near the back surface of the block, or could
extend inwardly from any wall of the block. The disclosure and
claims herein expressly extend to any suitable location for an
additional lift and alignment ring for blocks that have one or more
lift and alignment rings that do not overlie a longitudinal axis
that intersects the center of gravity for the block.
[0046] While the examples of walls shown in FIGS. 14-17 show
courses of main blocks on top of one or more courses of extended
blocks, this is shown by way of example, and is not limiting. The
blocks disclosed herein may be used in any suitable location or
combination. Thus, one could build a wall made entirely of extended
blocks, or could place one or more courses of extended blocks on
top of main blocks. Furthermore, while "courses" of blocks are
discussed herein, one skilled in the art will recognize that a
course need not have identical blocks. Thus, a single course could
include any suitable combination of blocks disclosed herein. This
provides an extremely versatile block system, because it allows
mixing and matching blocks according to specific needs.
[0047] The units herein are expressed in both English and metric
units. The preferred embodiments are implemented in English units,
and any variation between the stated English units and their metric
equivalents is due to rounding errors, with the English units being
the more correct measurement of the two.
[0048] The building blocks, system and methods disclosed herein
allow quick construction of a wall, such as a retaining wall, using
the blocks. The blocks include one or more lift and alignment
devices in the block that allow the block to be lifted using a
suitable lifting apparatus, such as a crane, forklift, backhoe,
etc. The blocks include one or more recessed portions in the bottom
surface of the block positioned to receive the protruding lift and
alignment device of a previously-laid block underneath, thereby
helping to align the block with the previously-laid block. The
block system includes a main block that has the lift and alignment
devices positioned to overlie a longitudinal axis that intersects a
center of gravity of the main block, and has a defined distance
from the lift and alignment devices to a front surface of the main
block. The block system further includes extended blocks that each
has the lift and alignment devices positioned not to overlie a
longitudinal axis that intersects a center of gravity of the
extended block, but has the same defined distance from the lift and
alignment devices to a front surface of the extended block that
exists on the main block. The recessed portions of the blocks may
be larger than the lift and alignment devices, thereby allowing the
blocks to be stacked in either a vertical wall or in a setback
wall. A block in the block system may include a mass extender on a
back of the block to improve the load-bearing capability of the
block.
[0049] A method for making a block includes the steps of
determining a center of gravity for the block, determining a
longitudinal axis that intersects the center of gravity for the
block, and positioning one or more lift and alignment rings
overlying the longitudinal axis.
[0050] While the invention has been particularly shown and
described with reference to preferred embodiments thereof, it will
be understood by those skilled in the art that various changes in
form and details may be made therein without departing from the
spirit and scope of the invention. For example, a block may be made
in a variety of different sizes. In addition, the size, number and
geometries of the block surfaces and voids in the block may vary
from that disclosed herein. Furthermore, while the block herein is
described as being used for retaining walls, it is equally within
the scope of the preferred embodiments to use the building block
for other purposes, such as building construction.
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