U.S. patent application number 14/081976 was filed with the patent office on 2014-05-22 for connection surface for a structural unit.
This patent application is currently assigned to KEYSTONE RETAINING WALL SYSTEMS LLC. The applicant listed for this patent is Robert A. MacDonald, Thomas S. Riccobene. Invention is credited to Robert A. MacDonald, Thomas S. Riccobene.
Application Number | 20140140766 14/081976 |
Document ID | / |
Family ID | 50728084 |
Filed Date | 2014-05-22 |
United States Patent
Application |
20140140766 |
Kind Code |
A1 |
Riccobene; Thomas S. ; et
al. |
May 22, 2014 |
CONNECTION SURFACE FOR A STRUCTURAL UNIT
Abstract
A connection surface that is disposed on at least a portion of a
face of a structural unit comprises a first convex surface and a
first concave surface arranged substantially along a first line.
The shape of the first concave surface is complementary to the
shape of the first convex surface. A second convex surface and a
second concave surface are arranged substantially along a second
line that is substantially parallel to the first line. The shape of
the second concave surface is complementary to the shape of the
second convex surface. The concave-convex order of the second line
is reversed relative to the first line, such that the second convex
surface corresponds with the first concave surface and the second
concave surface corresponds with the first convex surface.
Inventors: |
Riccobene; Thomas S.;
(Albuquerque, NM) ; MacDonald; Robert A.;
(Plymouth, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Riccobene; Thomas S.
MacDonald; Robert A. |
Albuquerque
Plymouth |
NM
MN |
US
US |
|
|
Assignee: |
KEYSTONE RETAINING WALL SYSTEMS
LLC
Minneapolis
MN
|
Family ID: |
50728084 |
Appl. No.: |
14/081976 |
Filed: |
November 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61727472 |
Nov 16, 2012 |
|
|
|
Current U.S.
Class: |
404/41 |
Current CPC
Class: |
E04F 13/0894 20130101;
E01C 5/00 20130101; E04F 2201/0107 20130101; E01C 2201/16 20130101;
E04B 2002/0215 20130101; E04F 2201/025 20130101; E02B 3/14
20130101; E04F 2201/022 20130101; E01C 2201/12 20130101 |
Class at
Publication: |
404/41 |
International
Class: |
E01C 5/00 20060101
E01C005/00 |
Claims
1. A connection surface disposed on at least one face of a
structural unit, the connection surface comprising: a first convex
surface and a first concave surface, the first convex surface and
first concave surface being arranged substantially along a first
line, the shape of the first concave surface being complementary to
the shape of the first convex surface; and a second convex surface
and a second concave surface, the second convex surface and second
concave surface being arranged substantially along a second line
that is substantially parallel to the first line, the shape of the
second concave surface being complementary to the shape of the
second convex surface; wherein a concave-convex order of the second
line is reversed relative to the first line such that the second
convex surface corresponds to the first concave surface and the
second concave surface corresponds to the first convex surface.
2. The connection surface of claim 1 wherein a first axis extends
between the first convex surface and the first concave surface and
the first concave surface is substantially a reflection of the
first convex surface about the first axis; and wherein the first
axis extends between the second convex surface and the second
concave surface and the second concave surface is substantially a
reflection of the second convex surface about the first axis.
3. The connection surface of claim 1 wherein the first concave
surface is complementary to the shape of both the first and second
convex surfaces and the second concave surface is also
complementary to the shape of both the first and second convex
surfaces.
4. The connection surface of claim 3, wherein a first axis extends
between the first convex surface and the first concave surface and
the first concave surface is substantially a reflection of the
first convex surface about the first axis; and wherein the first
axis extends between the second convex surface and the second
concave surface and the second concave surface is substantially a
reflection of the second convex surface about the first axis; and
wherein a second axis, perpendicular to the first axis extends
between the first convex surface and the second concave surface and
the second concave surface is substantially a reflection of the
first convex surface about the first axis; and wherein the second
axis extends between the second convex surface and the first
concave surface and the first concave surface is substantially a
reflection of the second convex surface about the second axis.
5. The connection surface of claim 3, wherein the first convex
surface and the second concave surface are arranged substantially
along a third line; the first concave surface and the second convex
surface are arranged substantially along a fourth line; the third
and fourth lines being substantially parallel; and the third and
fourth lines being substantially perpendicular to the first and
second lines.
6. The connection surface of claim 1 wherein the first and second
convex surfaces and first and second concave surfaces each comprise
at least one partial geometric solid.
7. The connection surface of claim 1 wherein the first and second
convex surfaces and first and second concave surfaces each comprise
irregular rock-like surfaces.
8. The connection surface of claim 1 wherein the connection surface
is an interior portion of the at least one face of the structural
unit.
9. The connection surface of claim 1 wherein the first convex and
first concave surfaces together define a first S profile, and
wherein the second concave and second convex surfaces together
define a second S profile that is symmetrical but reversed with
respect to the first S profile.
10. The connection surface of claim 9 wherein the first convex and
second concave surfaces together define a third S profile, and
wherein the second concave and first convex surfaces together
define a fourth S profile that is symmetrical but reversed with
respect to the third S profile.
11. A structural unit comprising: a plurality of faces; at least
one connection surface disposed on at least two of the plurality of
surfaces; wherein each connection surface comprises: a first convex
surface and a first concave surface, the first convex surface and
first concave surface being arranged substantially along a first
line, the shape of the first concave surface being complementary to
the shape of the first convex surface; and a second convex surface
and a second concave surface, the second convex surface and second
concave surface being arranged substantially along a second line
that is substantially parallel to the first line, the shape of the
second concave surface being complementary to the shape of the
second convex surface; wherein a concave-convex order of the second
line is reversed relative to the first line such that the second
convex surface corresponds to the first concave surface and the
second concave surface corresponds to the first convex surface.
12. The structural unit of claim 11 wherein the unit has a first
and opposite second face, each said face having a connection
surface thereon.
13. The structural unit of claim 11 wherein the first convex and
first concave surfaces together define a first S profile, and
wherein the second concave and second convex surfaces together
define a second S profile that is symmetrical but reversed with
respect to the first S profile; and wherein the first convex and
second concave surfaces together define a third S profile, and
wherein the second concave and first convex surfaces together
define a fourth S profile that is symmetrical but reversed with
respect to the third S profile.
14. A structure comprising: a plurality of structural units
including at least first and second structural units, each of the
plurality of structural units comprising a plurality of faces
including at least a first and second face, each of which having at
least one connection surface; wherein each connection surface
comprises: a first convex surface and a first concave surface, the
first convex surface and first concave surface being arranged
substantially along a first line, the shape of the first concave
surface being complementary to the shape of the first convex
surface; and a second convex surface and a second concave surface,
the second convex surface and second concave surface being arranged
substantially along a second line that is substantially parallel to
the first line, the shape of the second concave surface being
complementary to the shape of the second convex surface; wherein a
concave-convex order of the second line is reversed relative to the
first line such that the second convex surface corresponds to the
first concave surface and the second concave surface corresponds to
the first convex surface; wherein connection surfaces of the first
and second structural units are coupled such that the first and
second concave surfaces of the connection surface of the first
structural unit are at least partially receive the first and second
convex surfaces of the connection surface of the second structural
unit, and such that the first and second convex surfaces of the
connection surface of the second structural unit at least partially
receive the first and second convex surfaces of the connection
surface of the first structural unit.
15. The structure of claim 14 wherein a gap is defined between
mating faces of the first and second structural units, and wherein
the gap is at least partially filled with a resilient material.
Description
PRIORITY CLAIM
[0001] This application claims priority of U.S. Provisional
Application Ser. No. 61/727,472, filed Nov. 16, 2012.
FIELD OF THE INVENTION
[0002] The subject disclosure relates to pavers, edgers, wall
blocks, curbs, caps, precast wall panels, revetment mats, and other
structural units, and in particular to connectors for structural
units.
BACKGROUND OF THE INVENTION
[0003] It is well known to construct pavers, edgers, walls, curbs,
caps, precast wall panels, revetment mats, and other structures
with structural units. Such structural units can be manufactured
from concrete, clay, brick, plastic, or various other
materials.
SUMMARY OF THE INVENTION
[0004] An embodiment of the invention provides a connection surface
that is disposed on at least a portion of a face of a structural
unit. The connection surface comprises a first convex surface and a
first concave surface arranged substantially along a first line.
The shape of the first concave surface is complementary to the
shape of the first convex surface. A second convex surface and a
second concave surface are arranged substantially along a second
line that is substantially parallel to the first line. The shape of
the second concave surface is complementary to the shape of the
second convex surface. The concave-convex order of the second line
is reversed relative to the first line, such that the second convex
surface corresponds with the first concave surface and the second
concave surface corresponds with the first convex surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a top plan view of two connected structural units
according to a first embodiment of the invention.
[0006] FIG. 2a is a sectional view of the connected structural
units of FIG. 1, taken along line A-A and in the direction
indicated.
[0007] FIG. 2b is a sectional view of the connected structural
units of FIG. 1, taken along line B-B and in the direction
indicated.
[0008] FIG. 3a is an end view of one of the structural units of
FIG. 1.
[0009] FIG. 3b is an end view of another of the structural units of
FIG. 1.
[0010] FIGS. 4-5 are perspective views of a second embodiment
structural unit.
[0011] FIG. 6 is a perspective view of a third embodiment
structural unit.
[0012] FIG. 7 is a perspective view of two of the third embodiment
structural units with connection surfaces facing one another.
[0013] FIG. 8 is a perspective view of a fourth embodiment
structural unit having a beveled edge.
[0014] FIG. 9 is a perspective view of a fifth embodiment
structural unit having irregular edges to provide a more natural
stone appearance.
[0015] FIGS. 10-11 are perspective views of two fifth embodiment
structural units with connection surfaces facing one another, with
different ends of a second structural unit shown in FIGS. 10 and 11
respectively.
[0016] FIG. 12 is a perspective view of two of the fifth embodiment
structural units connected end-to-end to form an angle.
[0017] FIG. 13 is a perspective view of two of the fifth embodiment
structural units connected end-to-end to form a straight line.
[0018] FIG. 14 is a perspective view of one end of a wall section
including two courses of the fifth embodiment structural units (the
bottom rear structural unit is obscured) stacked in a half-bond
arrangement.
[0019] FIG. 15 is a perspective view of an opposing end of the wall
section of FIG. 14.
[0020] FIG. 16 is a front end perspective view of the wall section
of FIG. 14.
[0021] FIG. 17 is a front perspective view of the wall section of
FIG. 14.
[0022] FIG. 18 is a top perspective view of two trapezoidal
structural units according to a sixth embodiment with connection
surfaces facing one another.
[0023] FIG. 19 is a perspective view of the two sixth embodiment
structural units connected end-to-end to form a straight line,
where one of the structural units is reversed in orientation.
[0024] FIG. 20 is a close-up perspective view of the connection
surfaces of the two sixth embodiment structural units.
[0025] FIG. 21 is a perspective view of the two sixth embodiment
structural units with connection surfaces facing one another, where
both of the structural units have the same orientation.
[0026] FIG. 22 is a perspective view of the two sixth embodiment
structural units of FIG. 21 connected end-to-end to form a
curve.
[0027] FIGS. 23a-23b are perspective views of a seventh embodiment
structural unit having edges of convex portions that are partially
beveled.
[0028] FIGS. 24a-24c are perspective views of an eighth embodiment
structural unit having edges of convex portions that are separated
by a distance.
[0029] FIG. 25 is a perspective view of two ninth embodiment
structural units having connection surfaces with three-dimensional
shaped convex portions.
[0030] FIG. 26 is a perspective view of two tenth embodiment
structural units having connection surfaces with arch-shaped convex
portions.
[0031] FIG. 27 is an elevation view of a portion of an eleventh
embodiment wall having cruciform shaped structural units.
[0032] FIG. 28 is an elevation view of a portion of a twelfth
embodiment wall having hexagonal shaped structural units.
[0033] FIG. 29 is an elevation view of a portion of a thirteenth
embodiment wall having glide shaped structural units.
[0034] FIG. 30 is a plan view of three fourteenth embodiment paving
units connected and arranged in a 90/90/180 irregular rotation
arrangement, and showing areas of connection using connection
surfaces.
[0035] FIG. 31 is a perspective view of a fifteenth embodiment
structure including irregular rock connection surfaces.
[0036] FIG. 32 is a perspective view of a wall connected to a
pavement according to a sixteenth embodiment, in which wall blocks
and paving units include connection surfaces that connect to one
another.
[0037] FIG. 33 is a perspective view of a seventeenth embodiment
structural unit having a connection surface disposed on a
substantially central interior portion of an end face.
[0038] FIG. 34 is a perspective view of a portion of a wall
according to an eighteenth embodiment including rotated panels
connected to one another by connection surfaces disposed on side
faces.
[0039] FIG. 35 is a perspective view of an end face of a block
according to a nineteenth embodiment having a pair of connection
surfaces that are center rotations of one another about a
centerline.
[0040] FIG. 36 is a perspective view of a structural unit according
to a twentieth embodiment having a pair of connection surfaces
including a central connection surface disposed along a centerline
of a side face and an outer connection surface that is split and
disposed nearer to edges of the side face.
[0041] FIG. 37 is a perspective view of a structural unit according
to a twenty-first embodiment having two sets of connection surfaces
on a single end face to provide insets and offsets.
[0042] FIG. 38 is a perspective view of a portion of a connection
surface according to a twenty-second embodiment, in which the
convex and concave surfaces are arranged to allow offsetting in a
wall either backward or forward with triple sets.
[0043] FIG. 39 is a plan view of a connection surface according to
a twenty-third embodiment, in which the convex surfaces are domed
and separated from concave surfaces by a space.
[0044] FIG. 40 is a plan view of a connection surface according to
a twenty-fourth embodiment, in which the convex surfaces are
truncated pyramids.
[0045] FIGS. 41A and 41B are elevation views of two connected
convex surfaces of adjacent structural units according to a
twenty-fifth embodiment including external connection surfaces
disposed thereon.
[0046] FIG. 42 is an elevation view of a convex surface and a
concave surface of adjacent structural units according to a
twenty-sixth embodiment including external connection surfaces
disposed thereon.
[0047] FIG. 43 is a section view of two adjacent structural units
according to a twenty-seventh embodiment in which connection
surfaces are configured to allow movement in one direction, but
restrict movement in another.
DETAILED DESCRIPTION
[0048] Embodiments of the invention provide, among other things, a
connection surface disposed on at least a portion of a face of a
structural unit. Structural units, structures including structural
units, and methods for connecting structural units are also
provided herein. It will be understood that illustration and
description of connection structures will be applicable to
illustrate and describe connecting methods, and vice versa.
"Structural unit" refers to any unit that can used to form part of
a structure. A preferred structural unit is a concrete building
unit, including but not limited to pavers, concrete masonry units,
retaining wall blocks, patio stones, pavers, edgers, curbs, caps,
precast wall panels, and revetment mats.
[0049] Turning now to the drawings, FIGS. 1-3 illustrate a first
embodiment of the invention. First and second structural units,
namely blocks 10, 12 are shown having joined connection surfaces.
Block 10 includes a connection surface having vertical halves 14,
16 on a face of the block 10, and block 12 includes a connection
surface having vertical halves 18, 20 on the face of the block 12.
As used herein, a connection surface "on" a face of a structural
unit is intended to refer to a location on and/or in (partially or
fully) the face of the structural unit.
[0050] FIG. 3a depicts the connection surface of the first block
10. The connection surface includes a first convex surface 44 and a
first concave surface 40, extending substantially along a first
horizontal line. The first concave surface 40 in this embodiment
has an inward "V" shaped profile, and the first convex surface 44
has an outward "V" shaped profile that is complementary to the
first concave surface. As used herein the term "complementary"
means that the two surfaces have substantially the same
configuration such that a convex surface of one unit can be at
least partially received within a complementary concave surface of
another unit. The "complementary" surfaces need not be identical.
Extending along a second horizontal line that is parallel to the
first horizontal line are a second convex surface 42 and a second
concave surface 46. The second convex surface 42 has an outward "V"
shaped profile, and the second concave surface has a complementary
shaped inward "V" shaped profile. The first block 10 also has upper
and lower flat surfaces 48, 49, such that the connection surface is
disposed on an interior portion of the block face. In the first
block 10, the first concave surface 40 is also complementary to the
shape of the second convex surface 42, and the second concave
surface 46 is also complementary to the first convex surface 44,
though this is not required in all embodiments.
[0051] As further shown in FIG. 3a, a concave-convex order of the
second line is reversed relative to the first line. Particularly,
along the first line, the first convex surface 44 is disposed on
the left and the first concave surface 40 is disposed on the right,
while along the second line, the second concave surface 46 is
disposed on the left and the second convex surface 42 is disposed
on the right. In this way, the second convex surface 42 corresponds
with the first concave surface 40 and the second concave surface 46
corresponds with the first convex surface 42.
[0052] Similarly, FIG. 3b shows the connection surface of the
second block 12. Specifically, the connection surface includes a
first convex surface 50 and a first concave surface 54 extending
along a first horizontal line, and a second concave surface 52 and
a second convex surface 56 that extends along a second horizontal
line parallel to the first line. The first and second convex
surfaces 50, 56 have an outward "V" profile, and the first and
second concave surfaces 54, 52 have a complementary inward "V"
profile, so that the first convex surface is complementary to the
first concave surface, and the second convex surface is
complementary to the second concave surface. In block 12, the first
concave surface 54 is also complementary to the second convex
surface 56, and the second concave surface is also complementary to
the first convex surface 50.
[0053] Further, as with the first block 10, a concave-convex order
of the second line in block 12 is reversed relative to the first
line. Thus, along the first line, the first convex surface 50 is
disposed on the left and the first concave surface 54 is disposed
on the right, while along the second line, the second concave
surface 52 is disposed on the left and the second convex surface 56
is disposed on the right. The second convex surface 56 corresponds
with the first concave surface 54, and the second concave surface
52 corresponds with the first convex surface 50. The second block
12 in this example embodiment also has upper and lower flat
surfaces 58, 59.
[0054] Referring again to FIG. 3a, a first axis 70 extends (as
shown, vertically) between the first convex surface and the first
concave surface. The first concave surface 40 is substantially a
reflection of the first convex surface 44 about the first axis 70.
Further, the first axis 70 extends between the second convex
surface 42 and the second concave surface 46. The second concave
surface 46 is substantially a reflection of the second convex
surface 42 about the first axis 70. As used herein, "substantially"
refers to meeting or approximating a condition sufficiently to
provide a particular benefit, subject to manufacturing tolerances,
natural or designed imperfections, deliberate aesthetic features,
etc.
[0055] Additionally, in block 10, a second axis 72 extends (as
shown, horizontally) between the first convex surface 44 and the
second concave surface 46. The second concave surface 46 is
substantially a reflection of the first convex surface 42 about the
first axis 72. The second axis 72 also extends between the second
convex surface 42 and the first concave surface 46. The first
concave surface 46 is substantially a reflection of the second
convex surface 42 about the second axis. Similar axes can be
defined for block 12.
[0056] FIG. 2a shows two engagements of the example connection
surfaces for the blocks 10, 12. A first engagement 22 is formed
where convex surface 50 of block 12 is received in concave surface
40 of block 10. A second engagement 24 is formed where convex
surface 42 of block 10 is received in concave surface 52 of the
second block 12. The complementary surfaces of the units engaging
at 22, 24 forms a general S-shape as can be seen in FIG. 2a, herein
referred to as an "S-connection." This S-connection restrains
vertical movement between the blocks 10, 12.
[0057] Similarly (but reversed in direction), FIG. 2b shows an
engagement 32 wherein convex surface 44 of block 10 is received by
concave surface 54 of block 12. A second engagement 34 is formed
where convex surface 56 of block 12 is received in concave surface
46 of block 10. The complementary surfaces of the two units
engaging at 32, 34 also forms a general S-shape, albeit reversed,
which also restrains vertical movement.
[0058] Together, the S-connections of the vertical halves 14, 18
may be referred to as a "double S-connection." Further, because the
S-connections of the vertical halves are reversed with respect to
one another, lateral movement of the blocks 10, 12 with respect to
one another is constrained as well. Thus, the double S-connection
restrains both vertical and horizontal movement between the blocks
10, 12.
[0059] In the embodiment of FIGS. 1-3 the "S" shape of the
connection in the vertical plane is angular as shown in FIGS. 2a
and 2b. However, in other embodiments, as will become more apparent
below, the "S" shape maybe smoothly curved, box-shaped, regular or
irregular. Herein, the term "S-shape" or "S-connection" is used in
its broadest sense to mean any shape that is a center 180 degree
rotation having one end that is generally convex and the other end
being a substantially concave reflection thereof.
[0060] Further, in this embodiment, the mating block faces include
upper flat surfaces 48, 58 that engage at 26 in FIG. 2a, and the
lower flat surfaces 49, 59 engage at 28. In the present embodiment
the surfaces engaging at locations 22, 24, 26, 28, 32, 34 may
engage closely as shown, which would prevent the transmission of
light, sand, soil or other materials from one side of the block to
the other. However, in other embodiments, a gap may be provided
between one or more of the surfaces between the blocks 10, 12. The
gap(s) can remain open to provide permeability or can be filled
with other materials, such as neoprene, plastic or other resilent
materials during manufacture or installation. Also, one or more
engagements can be weight-bearing.
[0061] Because the convex/concave surfaces are reflections of one
another about the vertical and horizontal axes, the orientation of
the mating surface will be the same even when the block is
inverted. Thus, for example in the embodiment of FIGS. 1-3, if
block 12 is flipped over, it will still connect with block 10. This
is especially valuable for connecting non-rectangular blocks, e.g.,
trapezoidal and asymmetric shapes, as will be appreciated by
persons skilled in the art.
[0062] Various embodiments of structural units may have one or more
connection surfaces. Further, one or more connection surfaces may
be disposed at any structural unit face (plane, curved, irregular,
or other outer face of the structural unit), or in any portion or
portions of a face, and in any orientation. For example, a
structural unit may have ends, sides, top, bottom, or any other
face with one or more connection surfaces. Such connection surfaces
can occupy an entire face of a unit, or only a portion of the
structural unit face. Further, double S-connection surfaces can be
centered on a face, or can be off-center. All combinations of
connection surfaces, connection surface features (e.g., connection
surface features shown or described in any embodiment herein),
connection surface locations on a structural unit face, and
orientations are contemplated including but not limited by the
several embodiments shown and described herein. Structural units
can be connected end to end forward, turned, or flipped, or
otherwise connected in any combination to form surface coverings,
walls, edges and combinations thereof.
[0063] Connection surfaces can be provided on the face of the
structural unit, such as but limited to by being formed, e.g.,
molded or otherwise formed, into one or more faces of the
structural unit. For example, FIGS. 4-5 show second embodiment
structural units 80 having a double S-connection surface formed
therein.
[0064] Structural units can comprise, as non-limiting examples,
pavers, concrete masonry units (CMU), retaining wall blocks, patio
stones and edgers. Example structural units, including connection
surfaces, may be manufactured in any manner of substantially any
material such as, but not limited to, concrete (including wet cast
and dry cast), clay, plastic, ceramic, glass or composite
materials. Wet cast and dry cast concrete are preferred for
building units, such as pavers, CMU, retaining wall blocks, patio
stones and edgers, curbs, caps, precast wall panels, revetment
mats, and other units.
[0065] FIG. 6 shows a structural unit 84 according to a third
embodiment having a double S-connection surface. FIG. 7 shows the
connection surface of structural unit 84 facing juxtaposed to a
second, like structural unit 86, illustrating how the surfaces can
engage.
[0066] FIG. 8 shows a structural unit 88 according to a fourth
embodiment. Unit 88 has a first S-connection having a convex
surface 90 and complementary concave surface 92 that are in the
shape of a triangular prism. A second S-connection including convex
surface 94 and complementary concave surface 96 has a similar shape
to convex surface 90 and concave surface 92 but includes a beveled
edge to define truncated pyramids. As demonstrated by this
embodiment, the configurations of the two S-connections need not be
the same. Further, the two S-connections need not have the same
depth dimension. For example, the convex portion 94 of the
truncated pyramid-shape S-connection could project outwardly a
greater distance than the convex portion 90 of the triangular
prism-shaped S-connection to provide a spacing effect, or the
convex portion could have a shorter depth for creating space or
allowing movement.
[0067] The first and second convex and concave surfaces can be any
of various three-dimensional shapes, including solid geometric
shapes or irregular shapes. The convex and concave surfaces can
include at least one partial geometric solid. In some embodiments,
for instance, structural units can be configured to have a more
natural appearance, and thus include imperfections, textures,
slight mismatches, etc. The first concave surface, the first convex
surface, the second concave surface, and/or the second convex
surface can have a textured or non-textured outer surface. Example
surfaces can have irregular rock-like surfaces. The shapes can also
vary for particular applications, as will be appreciated by those
skilled in the art having reference to the present disclosure.
[0068] Rounded and/or irregular profiles provide a more natural,
stone-like appearance. For example, FIG. 9 shows a structural unit
100 according to a fifth embodiment having a double S-connection
surface that is generally rounded and irregular to provide a
natural, rock-like appearance. The rounded double S-connection
surface includes convex curved surface 104, which transitions to a
concave curved surface 106 along line S.sub.1. The surfaces 104,
106 are disposed between first 102 and second 108 generally
rock-like surfaces 108. Similarly, a convex curved surface 116
transitions to a concave curved surface 114 along line S.sub.2,
parallel to line S.sub.1. The second portion is disposed between
rock-like surfaces 112, 118. There is also a continuous transition
laterally between convex curved surface 104 and concave curved
surface 114 along horizontal line S.sub.3, and laterally between
concave curved surface 106 and convex curved surface 116 along
horizontal line S.sub.4. In this way, the lateral profiles of block
100 are also S-shaped along directions S.sub.3 and S.sub.4. Lines
S.sub.3 and S.sub.4 are substantially perpendicular to lines
S.sub.1 and S.sub.2. The convex and concave surfaces along lines
S.sub.1, S.sub.2, S.sub.3, S.sub.4 each define rounded, irregularly
shaped S-profiles. The numbering of lines S.sub.1-S.sub.4 is merely
for convenience and does not reflect priority or sequence. For
example, lines S.sub.3 and S.sub.4 can be considered as first and
second lines.
[0069] The S-profiles of lines S.sub.1, S.sub.2 are preferably
symmetrical but reversed with respect to one another, as is the
case with lines S.sub.3 and S.sub.4. However, it is not necessary
that the profiles of S.sub.1, S.sub.2 be the same as S.sub.3,
S.sub.4. Indeed, as one can observe from FIG. 9, S-connections
S.sub.1, S.sub.2 are shorter in length than S-connections S.sub.3,
S.sub.4. Although it is not strictly necessary, it is preferred
that the general configuration of the convex and concave surfaces
along lines S.sub.3 and S.sub.4 are complementary with one another.
Further, in the block 100 embodiment, the configurations of
convex-concave surfaces 104,106 and convex-concave surfaces 116,
114 are reflections of one another about a horizontal axis.
Thereby, one unit 100 can be flipped top-to-bottom and still mate
with another unit 100.
[0070] Structural units can be of essentially any shape. Example
shapes include rectangular, trapezoidal, cruciform, glides,
hexagonal or other polygonal, other geometric shapes, and
irregularly shaped units. Double S-connection surfaces can be
advantageously employed to connect and interlock adjacent
structural units in a wide variety of structures, including but not
limited to interior and exterior walls, retaining walls, pre-cast
wall panels, caps, columns and other vertical structures, as shown
for example in U.S. Pat. Nos. 3,394,521, 4,107,894, 6,557,818,
6,615,561 and 7,011,474; pavements, patios, walkways and other
surface coverings as shown for example in U.S. Pat. Nos. 4,128,357,
4,919,565 and 7,393,155; edgers and curbs, as shown for example in
U.S. Pat. No. 7,637,688; revetment mats, coast fortifications, and
other protective structures, as shown for example in U.S. Pat. Nos.
6,558,074 and 6,863,472. Double S-connection surfaces can be used
to join different size or shape structural units in multi-unit
systems, as shown for example in U.S. Patent Publication No.
2005/0166517. All of the foregoing cited patents and publications
are hereby incorporated by reference. Double S-connectors have
particularly advantageous application in tessellated surface
coverings comprising glides, flip glides, rotations, and other
types of tessellations--both regular and irregular. Further, double
S-connection surfaces can be utilized to join different types of
structures, such as walls-to-pavers, and pavers-to-curbs, as shown
in FIG. 32, for example.
[0071] FIGS. 10-13 show example structural units 120, 122 according
to the fifth embodiment that are generally trapezoidal in plan view
and have opposing ends with irregular double S-connection surfaces.
In FIG. 10, first ends 124 of structural units 120, 122 are
juxtaposed. In FIG. 11, first end 124 of structural unit 120 is
juxtaposed with a second end 126 of structural unit 122. FIG. 12
shows a course in which the structural units 120, 122 are connected
first end to first end to form an angle. Additional units 120, 122
can be connected to form a segmented arc or circle. FIG. 13 shows a
course in which the structural units 120, 122 are connected first
end to second end to form a straight line. This effect can be
achieved by flipping one unit top-to-bottom or turning one unit 180
degrees. Also, in a preferred embodiment, units 120, 122 include
false joints that contribute to the natural rock-like appearance.
Further, the connecting faces of the units 120, 122 do not engage
tightly leaving gaps of variable width but substantially the same
size and appearance as the false joints so that the mating faces
between units are not readily apparent.
[0072] Structural units may be respectively arranged in rows,
courses, columns, orthogonally, setback, rotationally, serpentine,
or other arrangements. In example wall embodiments, the structural
units are arranged to provide at least a second course on top of a
first course. One or more double S-connection surfaces can be
provided on the top and bottom faces of the units to thereby
restrain movement between units in the horizontal plane. The
structural wall units may also include double S-connection surfaces
on the ends or sides of the units to thereby restrain movement
between units in a vertical plane. Structural wall units in the
second course are preferably staggered from left to right with
respect to the structural units in the first course. Examples of
staggered arrangement include, but are not limited to, running
bond, half bond, quarter bond, three-quarter bond, etc. For
example, FIGS. 14-17 show wall sections including three blocks 130,
132, 134 according to the fifth embodiment. The blocks 130, 132,
134 are arranged in lower and upper courses having a half-bond
arrangement. Other, non-staggered arrangements are possible,
including stack bond arrangements. Blocks can be in a vertical
(near vertical) or setback arrangement as well. Optionally,
connection surfaces can be provided on top or bottom faces to
provide connection between courses, on faces, or both for
front-to-back connection. Courses with such connection surfaces can
be connected in a running bond, quarter bond, three-quarter bond or
other arrangements.
[0073] FIGS. 18-22 show structural units 140, 142 according to a
sixth embodiment, in which the structural units are generally
trapezoidal and have double S-connection surfaces on opposing end
faces. FIGS. 18-19 show the structural units 140, 142 respectively
in reverse orientation so that they are connected (FIG. 19)
end-to-end in a straight line. FIGS. 20-22 show the structural
units 140, 142 having the same orientation so that they are
connected (FIG. 22) end-to-end to form an angle. Complex courses,
such as serpentine courses, and structures having such courses, can
be provided by varying the orientation of arranged structural
units.
[0074] FIGS. 23a-23b show a structural unit 150 according to a
seventh embodiment in which edges 152, 154 of convex surfaces 156,
158 are partially beveled to aid installation by guiding adjacent
structural units into final position. More specifically, in the
FIG. 23 embodiment, convex surface 156 comprises a triangular prism
having a substantially vertical end 162 (best viewed in FIG. 23b)
and a beveled surface 160. Optionally, the beveled surface 160 can
extend all the way to the bottom of the concave portion.
[0075] FIGS. 24a-24c show a structural unit 170 according to an
eighth embodiment. In this embodiment, a double S-connection is
formed by off-setting faces 172, 174 such that convex portion 176
is aligned with concave portion 182 and convex portion 178 is
aligned with concave portion 184. A gap 180 is provided between the
faces 172, 174 for adjustment. The gap can be filled with
alternative materials, such as neoprene, plastic, etc., either
during manufacture or during installation. Alternatively, the gap
can be left open.
[0076] FIG. 25 shows double S-connection surfaces 202, 204 disposed
on the ends of structural units 206, 208 according to a ninth
embodiment. The connection surfaces 202, 204 include convex and
concave surfaces that are generally cubic or rectangular-prism
shaped. As discussed above, the "S" connection shape need not be a
smooth curve, but can be block format as in this embodiment. The
connection surfaces are disposed over the entire face, though in
other embodiments, the connection surfaces can be disposed over
less than the entire face. The fit between units need not be
perfect, and can be intentionally imperfect for aesthetic and/or
functional purposes.
[0077] FIG. 26 shows complementary connection surfaces 210, 212
disposed at end faces of structural units 214, 216 according to a
tenth embodiment. The connection surfaces 210, 212 include convex
and concave surface that are a partial/truncated cylindrical shape.
Connection surfaces can be load-bearing due to engagement of
complementary surfaces.
[0078] FIG. 27 is a plan view of a structure 220 according to an
eleventh embodiment that comprises a plurality of cruciform
structural units 222 assembled to form a panel or mat. The
structural units 222 are connected to one another via double
S-connection surfaces 224, two exemplary pairs being shown in FIG.
27. FIG. 28 is a plan view of structure 230 according to a twelfth
embodiment including hexagonal structural units 232, connected to
one another via pairs of double S-connection surfaces 234 (two
exemplary pairs are shown in FIG. 28). Additional pairs of
connector can be used as will be appreciated by those of ordinary
skill in the art. Mat structures can be used in highway walls or
embankments, waterway linings or banks, as shore protection, or
other applications as known in the art. The double S-connections of
the invention has particular application in waterways, as the
double S-configuration provides both lateral and vertical restraint
between units, which can prevent or reduce over-tipping, wherein
rapidly flowing water over the surface exerts an up-force on the
downstream edges of the structural units.
[0079] A surface covering, mat or panel structure can include
openings in various shapes, e.g., geometric or irregular. The
openings can be formed within units or can be defined spaces or
gaps between structural units. The openings can be left as an open
space, filled with permeable materials such as sand, filled organic
materials such as soil and plants, filled with cement, gout or
other adhesives, filled with cushioning materials, or even filled
with secondary units, which can in some embodiments have a
different shape, material composition and/or surface treatment as
compared to the primary structural units. Connection surfaces on
the mating sides of the joined structural units provide an easy
connection. Structural units combined in this way, with or without
secondary elements or other materials in openings, can be arranged
to define various patterns, providing aesthetic qualities.
Individual structural units, or groups of combined structural
units, alone or with secondary elements disposed within openings,
could be assembled as mats or panels. Cabling can run between
structural units, for instance as shown in U.S. Pat. No.
6,558,074.
[0080] FIG. 29 is a plan view of a glide structure 240 according to
a thirteenth embodiment comprising a plurality of curved structural
units 242 connected to one another via pairs of connection surfaces
244 (two exemplary pairs are shown).
[0081] FIG. 30 shows a portion of a surface covering 250 including
at least two surface covering units 252 according to a fourteenth
embodiment. The surface covering units 252 are irregular rotational
tessellation elements made in accordance with U.S. Pat. No.
7,393,155. One or more pairs of double S-connection surfaces 254
are provided to connect the units 252. These connection surfaces
254 can be split along a face of the surface covering units
252.
[0082] The double S-connection surface of the invention has
particular application to surface coverings units such as pavers
and patio stones. The double S-connection surfaces 250 provide a
double lock, restraining adjacent units from moving vertically with
respect to one another in addition horizontal restraint that
typically provided in conventional horizontal interlocking systems.
This can prevent a individual units in a surface covering from
tipping, sinking or being thrust upward due to an inconsistent
foundation, erosion, frost heave, or other causes. Further, a
pavement can be made permeable, e.g., water-permeable, if desired,
or substantially impermeable to light, sand, soil, etc.
[0083] FIG. 31 shows a structural unit 260 according to a fifteenth
embodiment. Unit 260 has connection surfaces 262a , 262b , 262c ,
262d , 262e , 262f disposed on all sides (three are visible in FIG.
31). It is also contemplated that the connection surfaces could be
on fewer than all sides, and on an interior portion of a particular
side or sides. While the structural unit 260 profile generally
defines a cube 264, the connection surfaces 262a -f in unit 260 are
configured to provide a "natural" irregular double S-connection.
Among other advantages, such a configuration allows multiple units
260 to stacked on a skid with adjacent units interlocking with each
other in both vertical and horizontal directions. Thereby, the
units "hug" one another reducing abrasion between units, breakage
and other damage in transportation. It is not required for all
surfaces of the building blocks 260 (or other structural units
disclosed herein) to touch, and gaps can be provided between units.
Preferably, the connection surfaces 262a , 262b , 262c , 262d ,
262e , 262f are configured to be substantially the same so that all
faces of the unit 260 can mate with all faces of similarly
configured units.
[0084] Structural units connected by double S-connection surfaces
may be of the same type, or of different types. FIG. 32 shows an
example structure 270 according to a sixteenth embodiment,
including a wall structural unit 272 that is connected to a paver
structural unit 274, which is in turn connected to a curb
structural unit 276. Mating double S-connection surfaces 278
disposed on opposing faces of the units 272, 274, 276 connect the
units, and thus different types of structures, to one another. Any
combinations of two or more structural unit types are contemplated
herein. Non-limiting examples include wall systems to paver
systems, retaining wall systems to paver systems, edger systems to
patios, walls to pavers and edgers, walls to caps, pavers to
curbings, precast wall panels to pavers, walls to revetment mats,
etc. Those of ordinary skill in the art will appreciate suitable
positions for connection surfaces for mating structural units of
different types.
[0085] The position of the connection surface on a face of a
structural unit can be over the entire face, or a portion of a
face. Further, where the connection surface is disposed on a
portion of a face, the connection surface can be disposed at any
location on the structural unit face. As one example, FIG. 33 shows
a structural unit 280 according to a seventeenth embodiment having
a connection surface 282 disposed on an end face 284, and located
at a central interior portion. The connection surface 282 can be
disposed away from the center of the face in other embodiments.
[0086] FIG. 34 shows a wall structure comprised of a plurality of
structural panel units 290 according to an eighteenth embodiment.
The panel units 290 include double S-connection surfaces 292
disposed at each of four end faces 294. Preferably the double
S-connection surface is centered on each end face. Accordingly,
each panel unit can be assembled in the same direction, alternative
directions, i.e., parquet as shown, or quarter turn.
[0087] Structural units can have more than one double S-connection
on a single face. FIG. 35 shows a structural unit 300 according to
a nineteenth embodiment having a pair of double S-connection
surfaces 302, 304 disposed on an end face 306 of the structural
unit 300. The connection surfaces 302, 304 can be configured as
images rotated about center line 308. It is also contemplated to
split the connection surface in half vertically, so that, for
instance, a single S is on top and a single S is on bottom. The
connection surface can also be split in half horizontally. Third,
fourth, or additional double S-connection surfaces can also be
provided on a single building unit surface or on a combination of
faces. When multiple double S-connection surfaces are employed,
each connector need not be the same size or shape as the other
S-connection surfaces. A full double S can be disposed on top and
bottom portions of the face 306, or a double S can be split and
disposed such that half is on top and half is on bottom, provided
that the halves are substantially equidistant from the center line
308.
[0088] FIG. 36 shows a structural unit 310 according to a twentieth
embodiment having a double S-connection surface disposed on a face
306. The double S-connection surface is split into first and second
portions 316a , 316b , each of which are substantially equidistant
from a center line 308. This arrangement helps resist tipping or
twisting of connected units. In the FIG. 36 embodiment, centers of
the first and second portions 316a , 316b are separated from
respective left and right edges at a quarter of the distance across
the length of the face 306, so that the center of first portion
316a is separated from each of the left edge and from the center
line 308 by a distance A, and the center of second portion 316b is
separated from each of the center line 308 and the right edge by
the same distance A. Split portions alternatively can be disposed
horizontally or vertically adjacent to one another. Optionally and
preferably, the double S-connection surfaces are spaced along the
side face of the unit so that the units can be assembled in 1/4,
1/2, 3/4 or stacked bond relationship.
[0089] FIG. 37 shows a structural unit 320 according to a
twenty-first embodiment having two sets of double S-connection
surfaces 322 on each end face 324. Any number of pairs or sets can
be provided. As provided above, one or more single units can also
be split down a center as well. This arrangement may be used to
generate recessed panels (I), projecting panels (P) or slanting
panels (S) in a wall or panel structure as shown in FIG. 38.
Specifically, by selectively mating inner connecting surfaces with
outer connecting adjacent panels can be recessed, projected or
slanted relative to each other. As one example, curves can be
provided by progressively stepping panels in/out relative to each
other. Spaces may be provided between concave surfaces and
complementary convex surfaces, in vertical and/or horizontal
directions. FIG. 39 shows a structural unit face 336 according to a
twenty-third embodiment, in which partial cylindrical convex
surface 338 and complementary concave surface 340 surfaces are
separated from one another by spaces 342. FIG. 40 shows another
unit face 350 according to a twenty-fourth embodiment similar to
connection surface 336, but with truncated pyramid shaped convex
338 and complementary concave 340 surfaces.
[0090] While some example embodiments include double S-connection
surfaces that are integrated, e.g., formed, into a face of a
structural unit, other embodiment double S-connection surfaces can
be alternatively or additionally provided by external elements that
are disposed on the face and are attached, adhered or otherwise
coupled to the face. External elements may include, as non-limiting
examples, convex and concave surfaces formed in any suitable
manner, such as by molding into an external face. The concave and
convex surfaces of such connection surfaces can be configured
similarly to any of the other concave and convex surfaces shown or
described elsewhere herein.
[0091] External elements may also be used as a key, and connected
to a receiving hole. For example, FIG. 41 shows two convex faces
350, 352 according to a twenty-fifth embodiment. The convex faces
350, 352 include insets 354, 356, in which are disposed external
double S-connection surfaces 358. For example, the external
connection surfaces 358 may be plugged into the insets 354, 356,
which provide a receiving core for the connection surfaces. The
connection surfaces 358 are configured according to any of the
connection surface embodiments disclosed herein. Alternatively, the
connection surface 358 can be integrated into the faces 350, 352.
FIG. 42 shows a convex face 360 and a concave face 362 according to
a twenty-sixth embodiment, which include opposing insets 364, 366,
each of which has an external double S-connection surface 368
disposed therein. The connection surface 368 can be configured
similarly to the external connection surface 358.
[0092] Example connection surfaces can be configured to allow some
movement in one direction providing a tighter restraint in another
direction. For example, FIG. 43 shows two structural units 370, 372
having connection surfaces 374, 376 configured such that a space
378 is defined between the units either along a vertical direction
(as shown in FIG. 43) or in a horizontal direction. One S is
visible in FIG. 43. The other S (not shown) preferably has
substantially the same spacing. Such a space can be provided by
controlling manufacturing tolerances, for instance, making the
concave surfaces deeper than the convex surfaces. Alternatively,
the concave surfaces can be made longer than the convex surfaces.
In the embodiment shown in FIG. 43, the space 378 allows the
structural units 370, 372 to move in a vertical direction with
respect to one another, while still constraining movement along the
horizontal direction. The space 378 can be fully or partially
filled with material, e.g., a pad (not shown) e.g., for cushioning,
or may be a clear space. To allow movement in the later direction,
a space may be provided such as space 180 (see FIG. 24b). A pad or
other material may be provided in the space 180.
[0093] Example connection surfaces, structural units, and
structures can include any combination of features shown and/or
described herein. The particular connection surface shown and
described herein are merely examples, and those of ordinary skill
in the art will appreciate that many other configurations for
connection surfaces are possible, and such additional
configurations are intended to fall under the scope of the present
invention.
[0094] Structures can be or include vertical, horizontal, flat,
curved, complex or irregular, largely two-dimensional, and/or
largely three-dimensional structures. Structures can include a
plurality of structural units, including any of the structural
units shown or described herein, including any combinations of
structural units, and including any of the connection surfaces,
including combinations of connection surfaces, shown or described
herein. The structure may be a complete, stand-alone structure, or
may be combined with other structural units to provide a larger
structure. Example structures include, but are not limited to,
walls (e.g., retaining walls, interior walls, exterior walls, sound
walls, etc.), wall veneers, wall panels, column blocks highway
panels, other panels, pavements, edges or combinations thereof.
[0095] While various embodiments of the present invention have been
shown and described, it should be understood that other
modifications, substitutions, and alternatives are apparent to one
of ordinary skill in the art. Such modifications, substitutions,
and alternatives can be made without departing from the spirit and
scope of the invention, which should be determined from the
appended claims.
[0096] Various features of the invention are set forth in the
appended claims.
* * * * *