A system of interlocking modular blocks for forming fence columns and fence panels is described.
Columnar structures used for decoration or as support for fence panels, gates or other such structures have required a considerable amount of skill and effort to erect. Conventional systems use mortared masonry blocks. Columns or pillars also have been made from stone, but this requires skilled craftspeople to ensure proper structural completion.
Modular blocks have also been used to build columns or pillars. Such blocks can be installed without special skill. The advantages to such blocks are that they are a convenient size to handle, a consistent size, and installation costs are less because of the lack of dependence on skilled labor. Blocks known in the art use construction adhesive or mortar to provide strength of connection and leveling between layers of blocks and may be used with mortar to simulate the appearance of a more conventional block and mortar column.
An important feature of the building blocks is their appearance. The look of weathered natural stone is very appealing for columns and other similar structures. The art provides several methods to produce concrete blocks having an appearance that to varying degrees mimics the look of natural stone. According to one well-known method, blocks are individually formed in a mold and the surfaces are textured by removal of the mold. Additional machine texturing processes can then be applied. The look of smooth cut stone can also be very attractive for columns and other structures. The smooth texture provides a more straight edge, formal, geometric shape for the block and overall structural appearance.
A need in this art remains for blocks that can be used to construct mortarless, sturdy, reinforceable columns that have a desired appearance.
This invention is a system of columnar blocks and stacking blocks configured to interlock with each other in the construction of fence panels and of a pilaster or column, respectively, in a fence. The columnar blocks are generally square and the stacking blocks are generally rectangular. The columnar blocks may be configured to be used with from one to four fence panels. Any exposed face of the blocks (i.e., that face visible to a viewer) preferably has a desired appearance, such as that resembling natural stone, or smooth to give a more formal appearance. The faces of the columnar blocks may contain one or more slots to give the resulting column or pilaster a more aesthetic appearance, such as that of a masonry joint. The appearance of the columnar block faces that interlock with fence panels may be smooth or textured to match the column finish.
The columnar blocks are provided with at least one interlocking element that permits a positive connection between courses of the blocks when the interlocking element is received in an overlying block. In one embodiment, the blocks interlock when there is a 90 degree rotation about a vertical axis of each block with each course. Also, these blocks may be placed over a pipe that is anchored into the ground. The core and the interlocking elements may be shaped to accommodate such a pipe. The columnar blocks can be used to construct a column with a natural stone-like appearance or smooth appearance depending upon which type of block is used. This building block system is designed to be easy to install and structurally sound.
When asymmetrical columnar blocks are used, such as in a corner of a wall, the location of the projections is varied so that there is a ‘left-hand’ and ‘right-hand’ block, and the projections of a ‘left-hand’ block will interlock into the core or void of the overlying ‘right-hand’ block.
The sides of the columnar block are provided with recesses into which fit the stacking blocks. The resulting block system is easy to install and structurally sound. The interlocking system makes the use of construction adhesive and other forms of mortar unnecessary, though such may still be used.
In this application, “upper” and “lower” refer to the placement of a columnar block in a column and a stacking block in a fence panel. The lower or bottom surface of blocks is the surface that faces the ground. Subsequent courses are formed by stacking blocks so that an interlocking element, projection, or “tongue” from one block fits into an indentation, void, or “groove” of an overlying block. “Top” and “bottom” surfaces are defined as those most conventionally used for these blocks, however, the blocks can be used with tops and bottom reversed.
The blocks of this invention may be made of a rugged, weather resistant material, such as concrete, especially if the columnar structure is constructed outdoors. Other suitable materials include plastic, reinforced fibers such as fiberglass, wood, metal and stone. Rather than being formed of a solid mass of material, the blocks may be hollow. That is, the blocks have the desired dimension, texture, and characteristics, but are hollow shells. This is an advantage in saving materials and in handling the block. Such hollow shell blocks can be formed of urethane or concrete and by casting techniques.
The surface of the blocks may be smooth or may have a roughened appearance, such as that of natural stone. The blocks are formed in molds and various textures can be formed on the surface, as is known in the art.
In typical use, the interlocking element extends above the top surface of the columnar block and projects into an indentation in an overlying block. In a preferred embodiment, the indentation is the same as the core; that is, the core extends through the thickness of the block. In one preferred embodiment, two interlocking elements extend above the top surface of the columnar block into the core of the overlying block, thus producing positive interconnection between facing surfaces. In a preferred embodiment, each successive block is rotated by 90 degrees about its vertical axis thus causing the interlocking elements to project into the indentation or core of the block above it. The interlocking elements hold the columnar blocks in place and eliminate the need for mortar when constructing the column.
For columnar blocks having a vertical axis of symmetry, the overlying block is rotated about its vertical axis and placed on the underlying block. The projections thus fit into the void created by the core. For columnar blocks that are asymmetrical, such as for a corner fence column, the blocks are not rotated as they are stacked, but rather, ‘left-hand’ and ‘right-hand’ blocks are provided, as described further below.
The faces of the blocks visible to a viewer are provided with a desirable surface appearance. These can be textured in a manner resulting in an appearance similar to that of natural stone, or can be smooth to give a more formal appearance. All four faces of the columnar block have substantially the same width and height. One or more faces of the columnar block optionally may contain one or more slots that will be visible in the columnar structure to give a column of blocks a more aesthetic appearance. This appearance may mimic mortared blocks, for example.
Rotation of each columnar block about its vertical axis also varies the location of the slot, if present, resulting in a more eye-pleasing pattern for the column. Rotation of the columnar blocks as a column is built also serves to produce a straight column. Because block molding processes may result in uneven blocks, stacking the blocks all in the same orientation may cause a column to tilt or lean. This problem is usually solved by shimming the blocks to make them level. With the column blocks of this invention, shimming is unnecessary.
The columnar block is provided with one or more recesses in one or more sides of the block. This recess is sized to accommodate an end of a stacking block. The column blocks and stacking blocks together form a system of blocks that forms a fence. Depending on the location of the recesses, a straight section, a corner section, a T-intersection, or a universal cross column can be constructed. The recesses in the columnar block optionally are provided with a passageway or channel. In this way, horizontal reinforcement can be used, if desired, to tie in a layer of stacking blocks to a columnar block in a column.
The stacking blocks form fence sections. Suitable stacking blocks are described in U.S. Pat. No. 6,176,049 (Crant et al.), hereby incorporated herein by reference. The stacking blocks have opposing top and bottom surfaces that have corresponding channels and projections so that the blocks interlock when stacked.
Columnar blocks of this invention also may be used with other blocks having interlocking elements, such as those described in commonly assigned, co-pending U.S. application Ser. No. 11/117,638 entitled “Column Block System,” filed on even date herewith (Attorney Docket Number KEY1033US), which claims the benefit of commonly assigned, co-pending U.S. Provisional application Ser. No. 60/566,528, filed Apr. 29, 2004 entitled “Column Block System,” both of which applications are hereby incorporated herein by reference.
Both vertically and horizontally interlocking fence systems can be constructed with the blocks of this invention.
Turning now to the drawings, the blocks of this invention are described.
Blocks 100 comprise top or upper surface 112a/b/c, bottom or lower surface 113a/b/c, first and second opposed sides 114a/b/c and 116a/b/c, and third and fourth opposed sides 115a/b/c and 117a/b/c. Top surface 112a/b/c is spaced apart from opposing lower surface 113a/b/c, thereby defining a block thickness. Opposed sides are substantially the same in width and height. The top and bottom surfaces 112a/b/c, 113a/b/c together with the first through fourth sides 114a/b/c to 117a/b/c form block body 100a/b/c.
The sides are provided with a desired appearance, as they will be visible to a viewer. Side 115a/b/c is additionally provided with trough or slot 109a/b/c. This slot is optional and is a decorative feature. The slot mimics the appearance of a mortar joint when a column of blocks is constructed. Sides 114a/b/c and 116a/b/c have recessed areas 124a/b/c and 126a/b/c, respectively, located generally centrally on each block side, and suitable for interlocking with a fence panel and/or stacking block as described further below.
The blocks are provided with core 120a/b/c, preferably located in the center of the block, which extends the thickness of the block. A core is desirable because it results in reduced weight for the block. The core is also useful when forming a column because vertical reinforcement can be inserted through the vertically aligned cores to lend stability to the columnar structure. For example, concrete grout and rebar, steel pipe, or post-tension rods can be used to fill the core and strengthen the structure. Various reinforcement materials are known in the art.
Block 100c, shown in
The surfaces of the block meet to form edges and corners. The corners may be beveled, chamfered or rounded to give a more weathered natural stone-like appearance.
Core 120a/b/c is generally rectilinear, having walls generally parallel to the side surfaces. On opposing inside corners of core 120a/b/c are located two interlocking elements 122a/b/c. These elements extend the thickness of the block, and project above the top surface of the block. They are essentially co-planar or parallel with the bottom surface of the block, that is, the bottom surface of the block is essentially co-planar or contiguous with the bottom surfaces of these elements. Although neither the interlocking elements nor the core need extend the thickness of the block, typically it is simpler to manufacture the blocks this way. In any event, the interlocking elements extend a distance above the top surface of the block. This distance is sufficient to provide adequate interlocking between blocks when a second columnar block is stacked on a first columnar block.
The interlocking elements are positioned both to align columnar blocks and lock them into place when they are stacked one upon another. That is, blocks 100a and 100b would be used together in a column. The position of the interlocking elements varies so that the columnar blocks can be stacked. Block 100c might be interlocked with corresponding similar columnar blocks (i.e., analogous to blocks 100b); however, block 100c can be used with blocks 100a and 100b in a column of blocks and horizontal reinforcement used in only one layer of the column.
In preferred embodiments, the interlocking elements are shaped so that a pipe connecting the column to its base or foundation can be installed vertically in the center of the columnar block and through the center of the column. That is, as shown in the figures, the portion of the projection facing the center of the core is curvilinear.
Blocks 200a/b comprise top or upper surface 212a/b, bottom or lower surface 213a/b (213a not shown), first and second opposed sides 214a/b and 216a/b, and third and fourth opposed sides 215a/b and 217a/b. Top surface 212a/b is spaced apart from opposing lower surface 213a/b, thereby defining a block thickness. Opposed sides have substantially the same height and width. The top and bottom surfaces together with the first, second, third, and fourth sides form a block body.
Sides 216a/b and 217a/b are provided with a desired appearance, as they will be visible to a viewer. Side 217a/b is additionally provided with optional trough or slot 209a/b. The blocks are provided with core 220a/b, preferably located in the center of the block, which extends the thickness of the block.
Block 200b, shown in
On opposing inside corners of core 220a/b are located two interlocking elements 222a/b. These elements extend the thickness of the columnar block, project above the top surface of the block, and are essentially co-planar with the bottom surface of the block.
Top 212b of block 200b is shown in
Block 300a/b comprises top or upper surface 312a/b, bottom or lower surface 313, first and second opposed sides 314a/b and 316a/b, and third and fourth opposed sides 315a/b and 317a/b. Top surface 312a/b is spaced apart from opposing lower surface 313, thereby defining a block thickness. The opposed sides have substantially the same height and width and each side has corresponding recessed areas 324a/b, 325a/b, 326a/b, and 327a/b. The top and bottom together with the first, second, third, and fourth sides form a block body.
Core 320a/b extends the thickness of the columnar block as shown in the bottom view of
Block 400 is shown in
Block 400 comprises top or upper surface 412, bottom or lower surface 413, first and second opposed sides 414 and 416, and third and fourth opposed sides 415 and 417. Top surface 412 is spaced apart from opposing lower surface 413, thereby defining a block thickness. Opposed sides have substantially the same width.
Optional slot 409 is located at a midpoint on side 415. The slot results in a desirable appearance of the columnar blocks, mimicking that of mortared blocks, and it aids in positioning the columnar block when forming a column.
Core 420 extends the thickness of the block. Core 420 is generally rectilinear, having walls generally parallel to the side surfaces. On opposing inside corners of core 420 are located two interlocking elements or projections 422. These elements extend the thickness of the block, and project above the top surface of the block. The bottom surface of the columnar block is essentially co-planar or contiguous with the bottom surfaces of these elements.
Block 500 has upper surface 512, lower surface 513, first and second opposed sides 514 and 516, and third and fourth opposed sides 515 and 517. Opposed sides are substantially the same in width and height. Side 515 has optional slot 509. Sides 514 and 516 have recessed areas 524 and 526, respectively, located generally centrally on each block side. The top and side edges of the block are chamfered.
Core 520 is located in the center of the block and extends the thickness of the block. Core 520 is generally rectilinear, having walls generally parallel to the side surfaces. On opposing inside corners of core 520 are located two interlocking elements 522, each having core 532. Adjacent each block corner is core 534. The cores can be seen in the top view in
The columnar blocks of this invention can be manufactured to any desired dimension. Typically, the thickness or height is about half the width of the columnar block. A desirable size for the columnar blocks is about 12 inches (30.4 cm) square (i.e., the maximum distance measured from side to side), and the thickness is about 6 inches (15.2 cm). The depth of the recessed area is about 1 inch (2.5 cm), and its width is about 6 inches (15.2 cm) so that it can accommodate the width of a stacking block. The U-shaped channel typically is about 3 inches (7.6 cm) deep. Block dimensions are selected not only to produce a pleasing shape for the desired column, but also to permit ease of handling and installation.
Two types of stacking blocks are used to construct a panel of a fence. As mentioned above, U.S. Pat. No. 6,176,049 (Crant et al.), incorporated herein by reference, describes suitable stacking blocks. A first stacking block is shown in
It is to be understood that the designations “top block” or “bottom block” is arbitrary and that the blocks could be stacked in the opposite orientation.
Block edges may be chamfered or beveled to provide an attractive appearance, and preferably the edge formed by the channel or groove in the top surface with the side surface is chamfered.
Stacking blocks 700 and 800 can be made in any desired dimensions, however, a convenient and attractive size for these blocks is about 6 inches (15.2 cm) wide and high, and 8 inches (20.3 cm) long. The core is about 3.5 inches (8.9 cm) in diameter. The U-shaped channel of block 800 is about 3.5 inches (8.9 cm) wide (i.e., as measured on a line perpendicular to the longitudinal axis). The channels and the projections are about 1 inch (2.5 cm) wide.
Base 901 is set into the ground to at least 24 inches (61 cm) or to frost depth depending on engineering requirements and local government building codes. For example, to construct column 910, block 200b (a left hand block, such as shown in
At the top of the fence is a capping layer comprising capping blocks 902. Various capping blocks are suitable for use in construction of a fence and are shown in
Stacking block 800 preferably is used in the same course as a columnar block having a side void (block 400) or a columnar block such as 100b, 200b, or 300b, depending upon the fence configuration. Stacking block 700 can be used with any columnar block, but typically would be used with blocks 100a, 200a, 300a, or 500.
Although particular embodiments have been disclosed herein in detail, this has been done for purposes of illustration only, and is not intended to be limiting with respect to the scope of the claims. In particular, it is contemplated that various substitutions, alterations and modifications may be made to the invention without departing from the spirit and scope of the invention as defined by the claims. For instance, the choice of materials or variations in the shape or angles at which some of the surfaces intersect are believed to be a matter of routine for a person of ordinary skill in the art with knowledge of the embodiments disclosed herein.
This application is a continuation of U.S. Ser. No. 11/117,640, filed Apr. 28, 2005, which claims the benefit of provisional application Ser. No. 60/566,590, filed Apr. 29, 2004, the contents of each of which are hereby incorporated herein by reference.
Number | Date | Country | |
---|---|---|---|
60566590 | Apr 2004 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 11117640 | Apr 2005 | US |
Child | 12057109 | US |