Modular wall block with mechanical course connector

Information

  • Patent Grant
  • 6701687
  • Patent Number
    6,701,687
  • Date Filed
    Thursday, May 8, 2003
    21 years ago
  • Date Issued
    Tuesday, March 9, 2004
    20 years ago
Abstract
A modular wall block is adapted for being assembled together with a number of other blocks in stacked courses to form a retaining wall. The wall block has a front and rear, top and bottom, and opposing sides. At least one of the opposing sides defines a generally L-shaped vertical slot. A course connector is received in the vertical slot, and includes first and second ends joined together by a setback spacer. The first end extends in an x-direction and a y-direction, and defines a generally L-shaped structure received in the L-shaped slot and restricting forward, rearward, and outward movement of the course connector. The second end of the course connector extends outwardly in a z-direction beyond one of the top and bottom of the wall block to engage one of the number of other blocks in an upper or lower course. The setback spacer locates the second end of the course connector a spaced distance from the first end to position the wall block in the retaining wall relative to the other blocks in the upper or lower course.
Description




TECHNICAL FIELD AND BACKGROUND OF INVENTION




This invention relates to a modular wall block including one or more mechanical course connectors, and a retaining wall constructed of an assembly of such blocks in stacked courses. The invention is particularly applicable for landscaping around residential and commercial structures to retain and preserve the surrounding soil while promoting the aesthetics of the area. As a result of its relatively low cost, ease of manufacture, and handling, concrete masonry block has emerged as one of the most popular and widely accepted material for use in constructing retaining walls. Blocks of this type are molded in a form.




Conventional retaining walls formed of concrete blocks are constructed in stacked courses with the ascending courses typically setback to counter the pressure of the soil acting against the wall. Mechanical means, such as geogrid mats or tie-backs, are commonly used to help stabilize the soil and further anchor the blocks in the wall. While such means are generally effective, a need exists in the industry for an improved course connector which mechanically interconnects the stacked block courses without interfering with placement or setback requirements, and which promotes stable, efficient, and precise construction of the retaining wall.




SUMMARY OF INVENTION




Therefore, it is an object of the invention to provide an improved wall block which uses course connectors to readily and conveniently position, align, and secure the blocks in stacked courses of the retaining wall.




It is another object of the invention to provide an improved wall block which uses a mechanical course connector to establish the setback of the block relative to an upper or lower course of blocks.




It is another object of the invention to provide an improved wall block which uses a mechanical course connector to achieve uniform and consistent setback throughout curves in the retaining wall.




It is another object of the invention to provide an improved wall block which is relatively lightweight and easy to handle.




It is another object of the invention to provide an improved wall block which is especially applicable for landscaping around plants and shrubs.




It is another object of the invention to provide an improved wall block with a rear portion adapted for being conveniently broken off and sides of reduced dimension, such that only a small portion of the block top is visible after backfilling with soil.




It is another object of the invention to provide an improved wall block which maximizes the available space surrounding the block for plantings.




It is another object of the invention to provide an improved course connector for use in combination with a wall block to position, secure, and align the block in a stacked course of the retaining wall.




It is another object of the invention to provide an improved course connector which extends in three mutually perpendicular directions.




It is another object of the invention to provide an improved course connector which is integrally molded of a relatively inexpensive material.




It is another object of the invention to provide an improved course connector which is formed in a variety of sizes to conveniently and accurately define the setback of the upper course block relative to the lower course blocks.




It is another object of the invention to provide an improved course connector which readily penetrates geogrid matting, and serves to further secure the matting between adjacent courses of the retaining wall.




It is another object of the invention to provide a retaining wall constructed of a number of like wall blocks.




These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a modular wall block adapted for being assembled together with a number of other blocks in stacked courses to form a retaining wall. The wall block has a front and rear, top and bottom, and opposing sides. At least one of the opposing sides defines a generally L-shaped vertical slot. A course connector is received in the vertical slot, and includes first and second ends joined together by a setback spacer. The first end extends in an x-direction and a y-direction, and defines a generally L-shaped structure received in the L-shaped slot of the wall block. When positioned in the wall block, movement of the course connector is restricted in all directions except upwardly towards the top of the block and downwardly towards the bottom. The second end of the course connector extends outwardly in a z-direction beyond one of the top and bottom of the wall block to engage one of the number of other blocks in an upper or lower course. The setback spacer locates the second end of the course connector a spaced distance from the first end to position the wall block in the retaining wall relative to the other blocks in the upper or lower course.




The terms “x, y, and z-directions” are used broadly herein to mean directions along respective axes which run parallel to Cartesian x, y, and z-axes, and which do not all pass through a single common point but which are mutually perpendicular in three dimensions.




According to another preferred embodiment, the setback spacer extends in a direction generally parallel to a portion of the first end of the course connector.




According to another preferred embodiment, the second end of the course connector forms an elongated vertical spike extending in the z-direction generally perpendicular to the setback spacer.




According to another preferred embodiment, the vertical spike and setback spacer of the course connector are integrally formed together at a center portion of the vertical spike, such that course connector is applicable for use on either of the opposing sides of the wall block.




According to another preferred embodiment, the vertical spike of the course connector defines opposing pointed ends adapted to facilitate penetration of the vertical spike through earthen backfill located behind the retaining wall.




According to another preferred embodiment, the course connector is integrally-formed of a molded material.




According to another preferred embodiment, the course connector is formed of a glass-filled nylon.




According to another preferred embodiment, the top of the wall block defines a lateral tie-back channel extending from one side of the block to the other. The channel is adapted for receiving an elongated tie-back element cooperating to anchor the block to earthen backfill behind the retaining wall.




According to another preferred embodiment, an edge defining the lateral channel is beveled to facilitate placement of the tie-back element in the wall block.




According to another preferred embodiment, an edge defining the vertical slot is rounded adjacent the top of the wall block for accommodating an anchor strap positioned in the lateral tie-back channel and extending rearwardly into earthen backfill behind the retaining wall.




According to another preferred embodiment, the front, rear, and opposing sides define a hollow core of the wall block.




According to another preferred embodiment, the sides of the wall block taper inwardly from the front to the rear.




According to another preferred embodiment, the opposing sides of the wall block are reduced relative to the front and rear to allow an increased amount of soil behind the front.




In another embodiment, the invention is a retaining wall constructed of a number of modular wall blocks assembled in stacked courses. Each of the wall blocks has a front and rear, top and bottom, and opposing sides. At least one of the opposing sides defines a generally L-shaped vertical slot. A course connector is received in the vertical slot, and includes first and second ends joined together by a setback spacer. The first end extends in an x and y-direction, and defines a generally L-shaped structure received in the L-shaped slot. When positioned in the wall block, movement of the course connector is restricted in all directions except upwardly towards the top of the block and downwardly towards the bottom. The second end of the course connector extends outwardly in a z-direction beyond one of the top and bottom of the wall block to engage one of the number of other blocks in an upper or lower course. The setback spacer locates the second end of the course connector a spaced distance from the first end to position the wall block in the retaining wall relative to the other blocks in the upper or lower course.











BRIEF DESCRIPTION OF THE DRAWINGS




Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the description proceeds when taken in conjunction with the-following drawings, in which:





FIG. 1

is a front perspective view of a wall block according to one preferred embodiment of the present invention, and showing a course connector located in the vertical slot of the block;





FIG. 2

is a rear perspective view of the wall block showing both course connectors located in respective vertical slots;





FIG. 3

is a top plan view of the wall block with the course connectors removed;





FIG. 4

is a front perspective view of a partially completed retaining wall formed using wall blocks of the present invention;





FIG. 5

is a rear perspective view of the retaining wall;





FIG. 6

is an enlarged, first perspective view of the course connector;





FIG. 7

is an enlarged, second perspective view of the course connector;





FIG. 8

is an enlarged, third perspective view of the course connector;





FIG. 9

is a rear perspective view of a partially completed retaining wall with geogrid matting arranged for placement between adjacent courses of the wall;





FIG. 10

is a front perspective view of a wall block according to a second preferred embodiment of the present invention; and





FIG. 11

is a rear perspective view of the wall block shown in FIG.


10


.











DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE




Referring now specifically to the drawings, a modular wall block according to the present invention is illustrated in

FIGS. 1-3

, and shown generally at reference numeral


10


. The wall block


10


is adapted for being assembled, as shown in

FIGS. 4 and 5

, with a number of like blocks in stacked courses “C” to form a retaining wall “W”. The wall blocks


10


are preferably formed of molded masonry concrete.




The wall block


10


has a front


11


and rear


12


, top


14


and bottom


15


, and opposing sides


16


and


17


. In one embodiment, the front


11


includes vertical breaks


18


and


19


defining a center face portion


11


A and opposing side face portions


11


B and


11


C. Preferably, the center face portion


11


A has an aesthetic, unfinished, rough textured surface. The core of the wall block


10


is hollow to reduce the overall weight of the block


10


, and for convenient handling and placement of the block


10


during construction of the retaining wall.




The sides


16


and


17


define respective vertical, L-shaped slots


21


and


22


extending through the wall block


10


from the top


14


to the bottom


15


. The vertical slots


21


,


22


are designed to receive mechanical course connectors


25


, described below, which operate to conveniently position, align, and secure the wall blocks


10


in the retaining wall “W”, as shown in

FIGS. 4 and 5

. Alternatively, the vertical slots


21


,


22


may extend only partially through the wall block


10


.




A single course connector


25


is illustrated in

FIGS. 6

,


7


, and


8


. The course connector


25


is preferably molded of a glass-filled nylon, and includes first and second ends


26


and


27


integrally joined together by a setback spacer


28


. The first end


26


extends in both an x-direction and y-direction, as indicated at


31


and


32


, respectively, and defines a generally L-shaped structure which is received in the corresponding vertical slot


21


,


22


of the wall block


10


. When properly positioned in the vertical slot


21


,


22


, movement of the course connector


25


is restricted in all directions except upwardly towards the top


14


of the block


10


and downwardly towards the bottom


15


. The elongated setback spacer


28


is integrally formed with the first end


26


of the course connector


25


, and extends in a direction perpendicular to the x-direction


31


of the first end


26


and parallel to the y-direction


32


of the first end


26


.




The opposite end of the setback spacer


28


is integrally formed with the second end


27


of the course connector


25


. The second end


27


extends perpendicular to the setback spacer


28


in a z-direction indicated at


33


. The second end


27


comprises a vertical spike


35


with opposing pointed ends


36


and


37


. When the blocks


10


are assembled in the retaining wall “W”, as shown in

FIGS. 4 and 5

, one of the spike ends


36


,


37


projects outwardly beyond the bottom


15


of the wall block


10


to engage one of the other stacked blocks


10


in a lower course. Preferably, the setback spacer


28


is joined at a center portion of the vertical spike


35


to form opposing identical spike ends, such that the course connector


25


is applicable for use in either the right or left side slot


21


,


22


of the wall block


10


. The pointed spike ends


36


and


37


facilitate penetration of the course connector


25


through soil backfill behind the retaining wall “W”, and through tie-back elements such as polyester geogrid matting sandwiched between courses “C”. The setback spacer


28


locates the vertical spike


35


a spaced distance from the first end


26


of the course connector


25


to position the wall block


10


in the retaining wall “W” relative to the other blocks


10


in the upper and lower course “C”. The degree of setback is controlled by the length of the spacer


28


. For example, a relatively short setback spacer


28


will result in greater setback from one stacked course to the next. A longer setback spacer


28


will result in less setback.




In alternative embodiments (not shown), the course connector may have a first end which extends in only a single x or y-direction, as previously defined, or which is hooked to hold the course connector in the wall block. The second end of the course connector may include only a single free end which may or may not be pointed. In addition, the first and second ends may extend at respective obtuse or acute angles relative to the setback spacer.




Referring to

FIGS. 1-3

and


9


, the top


14


of the wall block


10


defines a lateral tie-back channel


41


extending from one side of said block


10


to the other. The channel


41


is designed to receive a tie-back element, such as a flat elongated tie-back bar


42


shown in FIG.


9


. The tie-back bar


42


may span several wall blocks


10


, and resides inside the channel


41


between geogrid matting


44


and blocks


10


in an upper course “C”. The geogrid matting


44


anchors the blocks


10


to soil backfill behind the retaining wall “W”. Preferably, the edges defining the tie-back channel


41


are beveled to accommodate insertion of the tie-back bar


42


and geogrid matting


44


. In an alternative application, the tie-back element may be a elongated flexible tie-back strap (not shown) which extends through the channel


41


and rearwardly into the soil backfill. The back edge of each pair of edges defining respective vertical slots


21


,


22


in the wall block


10


is preferably rounded to accommodate proper placement and use of the strap. After assembling the blocks


10


, as described above, a course of molded concrete wall caps (not shown) is preferably laid over the top course to finish the retaining wall.




A further embodiment of a wall block


50


according to the present invention is shown in

FIGS. 10 and 11

. The smaller block


50


is especially applicable in commercial and residential landscaping. Like wall block


10


, block


50


has a front


51


and rear


52


, top


53


and bottom


54


, and opposing sides


55


and


56


. The front


51


includes vertical breaks


57


and


58


defining a center face portion


51


A and opposing side face portions


51


B and


51


C. The core of the wall block


50


is hollow and the sides


55


and


56


are reduced relative to the front


51


and rear


52


to substantially reduce the overall weight of the block


50


. The sides


55


,


56


define respective vertical, L-shaped slots


61


and


62


extending through the wall block


50


from the top


53


to the bottom


54


. The vertical slots


61


,


62


receive mechanical course connectors, identical to the connector


25


described above, which operate to conveniently position, align, and secure the blocks


50


in a landscape wall. To further reduce weight and promote handling, the rear


52


of the block


50


may be broken off using a hammer or other suitable tool. The reduced sides


55


,


56


allow increased placement of soil directly behind the front


51


of the block


50


to conceal a substantial portion of the top


53


, and to maximize the available surrounding space for plantings.




A wall block is described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.



Claims
  • 1. A modular wall block adapted for being assembled together with a number of other blocks in stacked courses to form a retaining wall, said wall block comprising:(a) a front and rear, top and bottom, and opposing sides, at least one of the opposing sides defining a generally L-shaped vertical slot; and (b) a course connector received in the vertical slot and comprising first and second ends joined together by a setback spacer, the first end extending in an x-direction and a y-direction and defining a generally L-shaped structure received in the L-shaped vertical slot to hold said course connector in said wall block, and the second end of said course connector extending outwardly in a z-direction beyond one of the top and bottom of said wall block to engage one of the number of other blocks in an upper or lower course, and said setback spacer locating the second end of said course connector a spaced distance from the first end to position said wall block in the retaining wall relative to the other blocks in the upper or lower course.
  • 2. A modular wall block according to claim 1, wherein the setback spacer extends in a direction generally parallel to a portion of the first end of said course connector.
  • 3. A modular wall block according to claim 1, wherein the second end of said course connector comprises an elongated vertical spike extending in the z-direction generally perpendicular to the setback spacer.
  • 4. A modular wall block according to claim 3, wherein the vertical spike and setback spacer of said course connector are integrally formed together at a center portion of the vertical spike, such that said course connector is applicable for use on either of the opposing sides of said wall block.
  • 5. A modular wall block according to claim 4, wherein the vertical spike of said course connector defines opposing pointed ends adapted to facilitate penetration of the vertical spike through earthen backfill located behind the retaining wall.
  • 6. A modular wall block according to claim 1, wherein said course connector is integrally-formed of a molded material.
  • 7. A modular wall block according to claim 6, wherein said course connector comprises a glass-filled nylon.
  • 8. A modular wall block according to claim 1, wherein the top of said wall block defines a lateral tie-back channel extending from one side of said block to the other, and adapted for receiving an elongated tie-back element cooperating to anchor said block to earthen backfill behind the retaining wall.
  • 9. A modular wall block according to claim 8, wherein an edge defining the lateral channel is beveled to facilitate placement of the tie-back element in said wall block.
  • 10. A modular wall block according to claim 9, wherein an edge defining the vertical slot is rounded adjacent the top of said wall block for accommodating an anchor strap positioned in the lateral tie-back channel and extending rearwardly into earthen backfill behind the retaining wall.
  • 11. A wall block according to claim 1, the front, rear, and opposing sides define a hollow core of the wall block.
  • 12. A wall block according to claim 1, wherein the opposing sides are reduced relative to the front and rear to allow an increased amount of soil behind the front.
  • 13. A retaining wall constructed of a number of modular wall blocks assembled in stacked courses, each of said wall blocks comprising:(a) a front and rear, top and bottom, and opposing sides, at least one of the opposing sides defining a generally L-shaped vertical slot; and (b) a course connector received in the vertical slot and comprising first and second ends joined together by a setback spacer, the first end extending in an x-direction and a y-direction and defining a generally L-shaped structure for being received in the L-shaped vertical slot to hold said course connector in said wall block, and the second end of said course connector extending outwardly in a z-direction beyond one of the top and bottom of said wall block to engage one of a number of other blocks in an upper or lower course, and said setback spacer locating the second end of said course connector a spaced distance from the first end to position said wall block in the retaining wall relative to the other blocks in the upper or lower course.
  • 14. A retaining wall according to claim 13, wherein the setback spacer extends in a direction generally parallel to a portion of the first end of said course connector.
  • 15. A retaining wall according to claim 13, wherein the second end of said course connector comprises an elongated vertical spike extending in the z-direction generally perpendicular to the setback spacer.
  • 16. A retaining wall according to claim 15, wherein the vertical spike and setback spacer of said course connector are integrally formed together at a center portion of the vertical spike, such that said course connector is applicable for use on either of the opposing sides of said wall block.
  • 17. A retaining wall according to claim 16, wherein the vertical spike of said course connector defines opposing pointed ends adapted to facilitate penetration of the vertical spike through earthen backfill located behind the retaining wall.
  • 18. A retaining wall according to claim 13, wherein said course connector is integrally-formed of a glass-filled nylon.
  • 19. A retaining wall according to claim 13, wherein the top of said wall block defines a lateral tie-back channel extending from one side of said block to the other, and adapted for receiving a tie-back element cooperating to anchor said block to earthen backfill behind the retaining wall.
  • 20. A modular wall block according to claim 19, wherein an edge defining the lateral channel is beveled to facilitate placement of the tie-back element in said wall block.
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