RETAINING WALL BLOCK SYSTEM

Abstract

A masonry block, comprising a front face, a rear face disposed opposite the front face, a first side face disposed between the front face and the rear face, a second side face disposed between the front face and the rear face and opposite the first side face, a top face disposed adjacent to the front face, the rear face, the first side face and the second side face, a bottom face disposed opposite to the top face and adjacent to the front face, the rear face, the first side face and the second side face and wherein the top face includes a slot extending from the first side face to a point between the first side face and the second side face, the slot including a first sub slot extending orthogonal to the slot in the top face.

Description

TECHNICAL FIELD

The present disclosure relates generally to masonry blocks, and more specifically to a retaining wall block system that includes blocks having a slot extending partially across one face, with a plurality of pin apertures.

BACKGROUND OF THE INVENTION

Retaining walls can be constructed from blocks, but there is often a trade-off between the complexity of the design of the wall block, the ease of installation of the wall block and the ease of manufacture of the wall block.

SUMMARY OF THE INVENTION

A masonry block is disclosed that includes a front face, a rear face disposed opposite the front face, a first side face disposed between the front face and the rear face and a second side face disposed between the front face and the rear face and opposite the first side face. A top face is disposed adjacent to the front face, the rear face, the first side face and the second side face, and a bottom face is disposed opposite to the top face and adjacent to the front face, the rear face, the first side face and the second side face. The top face includes a slot extending from the first side face to a point between the first side face and the second side face, and the slot includes a first sub slot extending orthogonal to the slot in the top face.

Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings may be to scale, but emphasis is placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views, and in which:

FIG. 1 is a diagram of a block, in accordance with an example embodiment of the present disclosure;

FIG. 2 is a top view of a block, in accordance with an example embodiment of the present disclosure;

FIG. 3 is a diagram of a block showing a front face, a bottom face, a side face, a slot and a slot penetration;

FIG. 4 is a diagram showing a top view of the ornamental design of a block, in accordance with an example embodiment of the present disclosure;

FIG. 5 is a diagram showing a bottom view of the ornamental design of a block, in accordance with an example embodiment of the present disclosure;

FIG. 6 is a diagram showing a side view of the ornamental design of a block, in accordance with an example embodiment of the present disclosure;

FIG. 7 is a diagram showing a different side view of the ornamental design of a block, in accordance with an example embodiment of the present disclosure;

FIG. 8 is a diagram showing a front view of the ornamental design of a block, in accordance with an example embodiment of the present disclosure;

FIG. 9 is a diagram showing a rear view of the ornamental design of a block, in accordance with an example embodiment of the present disclosure;

FIG. 10 is diagram showing a block assembly, in accordance with an example embodiment of the present disclosure;

FIG. 11 is diagram showing a block assembly with pins, in accordance with an example embodiment of the present disclosure; and

FIG. 12 is diagram showing a wall assembly, in accordance with an example embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures may be to scale and certain components can be shown in generalized or schematic form and identified by commercial designations in the interest of clarity and conciseness.

The present disclosure is directed to masonry blocks that can be formed from concrete, marble, granite, limestone, cast stone, glass, adobe, composite materials or other suitable materials. The blocks can be formed using a wet cast process, a dry cast process, a dry tamp process or other suitable processes, and can be formed with the relative dimensions shown or other suitable dimensions. The blocks can be assembled into walls using glue, mortar, pins or other suitable connecting materials or devices, and can be assembled on a concrete pad, a leveling pad, drainage pipes, geogrids, soil stabilization grids or mats or other suitable processes or materials.

In general, “upper” and “lower” may refer to a current view of a block, the placement of a block in a retaining wall or in other suitable configurations, such as where an upper surface of a block shown in a drawing is inverted and becomes a lower surface of the block when installed. The lower or bottom surface can be placed so that it faces the ground or other structural foundation. In a retaining wall, one row of blocks is typically laid down first to form a first course, and an upper course is typically formed on top of the first course by positioning the lower surface of one block on the upper surface of another block. However, the disclosed embodiments can be used in other suitable applications and are not limited to any specific intended use.

The present disclosure includes a block system that can include multiple sizes of blocks with differently dimensioned, interchangeable front and back faces. The blocks can be used to construct a retaining wall or other suitable structures.

The blocks can be provided with pin-receiving apertures and channels, which, along with pins (not explicitly shown) or other suitable devices that are adapted to be received in the pin-receiving apertures, can be used to form an attachment system among the blocks in a wall. A suitable number of apertures can be used, but in some of the disclosed embodiments, there are at least six pin-receiving apertures. The apertures can be disposed perpendicular to first and second faces of the block.

FIG. 1 is a diagram of a block 100, in accordance with an example embodiment of the present disclosure. Block 100 includes a front face 102 and an opposite rear face (not shown), a side face 104 and an opposite side face (not shown), a top face 106 and an opposite bottom face (not shown), a beveled edge 108 and a slot 110. While beveled edges are shown along the top and sides of block 100, the edges can be rounded or square, the bottom edges of block 100 can also or alternatively be beveled or rounded, the number of beveled top edges or side corners can be reduced where suitable, and other suitable variations can also or alternatively be used. Slot 110 can include a plurality of apertures for pins that can be used to secure the position of a block relative to other blocks. The pin can include a shoulder or head portion affixed to a body portion, and can fit within the aperture.

Top face 106 is opposed to and substantially parallel to a lower surface that is not shown in FIG. 1. Side face 104 can be planar, roughened or can have other suitable configurations, and can be disposed perpendicular to front face 102. Front face 102 can have a greater surface area than side face 104. Front face 102 and side face 104 can be joined by and orthogonal to top face 106, where an angle formed by an imaginary line coincident with front face 102 and an imaginary line coincident with top face 106 is 90 degrees. Front face 102 and side face 104 can also be joined to the bottom surface. Similarly, the angle formed between side face 104 and top face 106 can be 90 degrees. Block 100 can be provided with a through-passage or core as well as with pin-receiving apertures, as will be described in greater detail. The lower surface of the block can be provided with the pin-receiving apertures and can be parallel to top face 106 of block 100.

Block 100 can be manufactured to a desired thickness. The dimensions of block 100 can be selected not only to produce a pleasing shape for the retaining wall, but also to permit ease of handling and installation. Typically one thickness of block 100 is used to construct a retaining wall. The width of block 100 is defined as the distance from front face 104 to the opposite face, as measured at a midpoint. For use in retaining walls, block 100 of this invention can be manufactured to have approximately the same length and various widths.

The sides of block 100 can be tapered. That is, for example, the surface area of the bottom face of block 100 may be larger than the surface area of top face 106 of block 100. Tapering is typically a result of the manufacturing processes when removing a block from its mold.

Block 100 can be provided with a core or passageway, as will be described further herein, which can be located generally at the center of the block. The core can extend through the thickness of the block. The dimension of the core can be varied as desired, and can taper as shown and described herein or can have other suitable dimensions. Providing a core can result in a reduced weight for the block and can also permit easier handing during installation of a retaining wall. The core can also be useful when forming parapet walls, because concrete grout can be used to fill the cores and strengthen the wall. Blocks having cores can be aligned so that a wall can be reinforced with tension rods. Railing posts can be used as anchors in the cores.

Cores can also provide additional support to the manufacturing equipment, such as the mold. During the compaction of the material, when the machine stripper head enters the mold bottom, it can hit or come in contact with parts in the mold bottom. Some of these parts are fragile and prone to breakage. These cores give added strength and support against this contact and are a manufacturing improvement.

Block 100 can be provided with pin-receiving apertures. These apertures can be provided as it is desirable to use pins to secure and align the blocks, attach a geogrid, and/or provide shear resistance.

The FIGURES illustrate blocks having one or two sets of three offset pin-receiving apertures that can be arranged perpendicular to top face 106 and its opposite face. Although not explicitly shown, the apertures can penetrate entirely through the blocks, or can be formed with a break-away layer to allow the pins to penetrate through the break-away layer when desired. Likewise, other suitable configurations of pins can also or alternatively be used, consistent with the teachings of the present disclosure.

The manufacturing equipment such as the mold bottom and parts that make the pin-receiving apertures can be configured to hang down to the mold bottom. When the production pallet is placed underneath the mold, these parts can be configured not come into contact with the production pallet, as masonry material can get caught between the pin-receiving aperture inset and the production pallet, which can break the pin-receiving aperture inset. The pin-receiving aperture insets and related parts can be spaced from the production pallet, to prevent damage from material between them and the production pallet. This space helps to prevents the breakage of these parts, and can be sized such that material will not fill in this area. While this configuration can be used to form the hole of the pin-receiving apertures, if the mold includes an increased gap size to prevent breakage, the thin break away area described herein can be formed.

FIG. 2 is a top view of block 200, in accordance with an example embodiment of the present disclosure. Pins can be used in pin-receiving apertures 202, 204, 206, 210, 212 and 214, to hold the courses of blocks in place, although in some applications such as where the wall design is simple, the weight of the blocks may sufficient to hold the blocks in place. The pin-receiving apertures are disposed in slot 110, which can extend along top face 106, perpendicularly from the face opposite from side face 104. Two orthogonal sub-slots can be formed in slot 110 to contain pin-receiving apertures 202/204 and 210/212, respectively, with additional pin-receiving apertures 206 and 214 disposed in the main portion of slot 110 or in other suitable locations.

The size and configuration of slot 110 and pin-receiving apertures 202, 204, 206, 210, 212 and 214 can be selected to improve the stability of walls formed from block 200, such as to reduce the shear stress that is placed on connecting pins, to increase the options for overlapping and staggering blocks 200, to facilitate installation, to facilitate placement of caps, and for other suitable purposes. In addition, the size and configuration of slot 110, pin-receiving apertures 202, 204, 206, 210, 212 and 214 and slots 208 and 216 provides additional manufacturing advantages, such as the reduction in complexity relative to other retaining wall blocks, reduction of difficulty of determining a proper orientation of a block during installation and other technical features. For example, the arrangement of slot 110 facilitates the ability to determine the correct orientation of the top and bottom of a block, the correct orientation of the left and right sides of a block, the correct orientation of the front and back of a block, as well as other technical features.

FIG. 3 is a diagram of a block 300 showing front face 102, bottom face 302, side face 304, slot 216 and slot penetration 306. Block 300 can be complementary to blocks 100 and 200, where bottom face 302 is opposite from top face 106 of block 100, side face 304 is opposite from side face 104 of block 100, slot 216 and slot penetration 306 is the extension of slot 208 into bottom face 302. In this manner, the orientations and dimensions discussed in regards to blocks 100 and 200 are applicable to block 300. While the pin apertures 308, 310, 312, 314, 316 and 318 are not shown extending through block 300, they can be manufactured to be present, and as discussed further herein can include a break-out layer that allows pins to be inserted when desired, or can be provided in other suitable manners and configurations.

FIG. 4 is a diagram showing a top view of the ornamental design of block 400, in accordance with an example embodiment of the present disclosure. Block 400 includes a combination of functional and ornamental features, where the ornamental features include the look and feel of block 400 that creates an attractive and distinctive appearance that a consumer can easily identify. While there are a number of ways to provide a block with the same functional features of block 400, the ornamental features are selected for aesthetic reasons and to provide a distinctive ornamental design.

FIG. 5 is a diagram showing a bottom view of the ornamental design of block 500, in accordance with an example embodiment of the present disclosure. Block 500 includes a combination of functional and ornamental features, where the ornamental features include the look and feel of block 500 that creates an attractive and distinctive appearance that a consumer can easily identify. While there are a number of ways to provide a block with the same functional features of block 500, the ornamental features are selected for aesthetic reasons and to provide a distinctive ornamental design. The dashed lines correspond to the pin apertures, which can either be present or blocked, as discussed further herein.

FIG. 6 is a diagram showing a side view of the ornamental design of block 600, in accordance with an example embodiment of the present disclosure. Block 600 includes a combination of functional and ornamental features, where the ornamental features include the look and feel of block 600 that creates an attractive and distinctive appearance that a consumer can easily identify. While there are a number of ways to provide a block with the same functional features of block 600, the ornamental features are selected for aesthetic reasons and to provide a distinctive ornamental design.

FIG. 7 is a diagram showing a different side view of the ornamental design of block 700, in accordance with an example embodiment of the present disclosure. Block 700 includes a combination of functional and ornamental features, where the ornamental features include the look and feel of block 700 that creates an attractive and distinctive appearance that a consumer can easily identify. While there are a number of ways to provide a block with the same functional features of block 700, the ornamental features are selected for aesthetic reasons and to provide a distinctive ornamental design.

FIG. 8 is a diagram showing a front view of the ornamental design of block 800, in accordance with an example embodiment of the present disclosure. Block 800 includes a combination of functional and ornamental features, where the ornamental features include the look and feel of block 800 that creates an attractive and distinctive appearance that a consumer can easily identify. While there are a number of ways to provide a block with the same functional features of block 800, the ornamental features are selected for aesthetic reasons and to provide a distinctive ornamental design.

FIG. 9 is a diagram showing a rear view of the ornamental design of block 900, in accordance with an example embodiment of the present disclosure. Block 900 includes a combination of functional and ornamental features, where the ornamental features include the look and feel of block 900 that creates an attractive and distinctive appearance that a consumer can easily identify. While there are a number of ways to provide a block with the same functional features of block 900, the ornamental features are selected for aesthetic reasons and to provide a distinctive ornamental design.

In one example embodiment, the disclosed designs can be assembled in an ordered or random placement of identical or differently sized wall blocks for use in a retaining wall. The blocks can be disposed in a first layer in a trench to form the base layer, where blocks having the same or various widths are placed in an ordered manner, are randomly placed or are otherwise suitably arranged. The different faces can have different surface areas where suitable, and the orientation of the blocks can be selected to create an ordered appearance, a random appearance or other suitable designs. A cap layer can be provided to cover the slots and retaining pins.

FIG. 10 is diagram showing a block assembly 1000, in accordance with an example embodiment of the present disclosure. Block assembly 1000 includes block 1002 and block 1006 on a bottom layer and block 1004 on a top layer, with a rear offset between the bottom layer and the top layer. Pins 1008 and 1014 are shown disposed in a hole in the cross-slot of blocks 1002 and 1006, respectively, with additional empty holes 1010 and 1012 in block 1002 and empty holes 1016 and 1018 in block 1006. In this manner, the slot on the bottom surface of block 1004 can be aligned with the pins, to provide an offset relative to blocks 1002 and 1006. Likewise, pins 1008 and 1014 could alternatively be disposed in empty holes 1010 and 1016 to align block 1004 directly over blocks 1002 and 1006, or in empty holes 1012 and 1018 to offset block 1006 forward of blocks 1002 and 1006. Likewise, the ends of block 1004 are located at the midpoints of blocks 1002 and 1006, in a half or running bond position, but alternatively a stack bond, English bond, Flemish bond, common bond or other suitable configurations can be formed, assuming blocks having suitable dimensions have been fabricated. A person of skill in the art will understand that dimensions for blocks can be selected to allow such configurations to be formed. Pin 1008 can also be disposed in one of holes 1010 or 1012, to provide a slight turn of block assembly, or pin 1014 could be disposed in one of holes 1016 or 1018, to provide a slight turn in a different direction. In this manner, pins can be placed to allow a wall to be formed in a non-linear configuration, such as to follow the curvature of a terrain feature or for other suitable purposes.

FIG. 11 is diagram showing a block assembly 1100 with pins 1102 and 1104, in accordance with an example embodiment of the present disclosure. Additional pins are disposed but not shown in blocks 1108 and 1110 to align block 1106, such as in the manner shown in block assembly 1000, to offset or align block 1004 as desired. Pins 1102 and 1104 are then used for alignment of additional blocks that can be used to form a second course of blocks on top of blocks 1108 and 1110.

FIG. 12 is diagram showing a wall assembly 1200, in accordance with an example embodiment of the present disclosure. Wall assembly 1200 can be fabricated using the configurations shown in block assembly 1000 and 1100, and includes a cap layer 1202 on top of a first layer 1204 and a second layer 1206. The first layer 1202 is arranged in a half or running bond configuration on top of second layer 1206, but other suitable configurations can also or alternatively be used.

A masonry block is disclosed that includes a front face, a rear face disposed opposite the front face, a first side face disposed between the front face and the rear face, a second side face disposed between the front face and the rear face and opposite the first side face, a top face disposed adjacent to the front face, the rear face, the first side face and the second side face, a bottom face disposed opposite to the top face and adjacent to the front face, the rear face, the first side face and the second side face and wherein the top face includes a slot extending from the first side face to a point between the first side face and the second side face, the slot including a first sub slot extending orthogonal to the slot in the top face. The masonry block can further comprise one or more pin-receiving apertures. The masonry block can further comprise one or more pin-receiving apertures disposed in the slot and one or more pin-receiving apertures disposed in the first sub slot. The masonry block can further comprise a second sub slot extending orthogonal to the slot in the top face. The masonry block can further comprise one or more pin-receiving apertures disposed in the slot, one or more pin-receiving apertures disposed in the first sub slot and one or more pin-receiving apertures disposed in the second sub slot. The masonry block can further comprise a second sub slot extending orthogonal to the slot in the top face and parallel to the first sub slot. The masonry block can further comprise one or more pin-receiving apertures disposed in the slot, one or more pin-receiving apertures disposed in the first sub slot and one or more pin-receiving apertures disposed in the second sub slot. The masonry block can further comprise a core disposed in the masonry block.

A wall is disclosed that includes a first masonry block having a front face, a rear face disposed opposite the front face, a first side face disposed between the front face and the rear face, a second side face disposed between the front face and the rear face and opposite the first side face, a top face disposed adjacent to the front face, the rear face, the first side face and the second side face, a bottom face disposed opposite to the top face and adjacent to the front face, the rear face, the first side face and the second side face and wherein the top face includes a slot extending from the first side face to a point between the first side face and the second side face, the slot including a first sub slot extending orthogonal to the slot in the top face, a second masonry block disposed on top of the first masonry block and having a core and a pin disposed in the slot and extending into the core. The wall can further comprise one or more pin-receiving apertures in the first masonry block. The wall can further comprise one or more pin-receiving apertures disposed in the slot and one or more pin-receiving apertures disposed in the first sub slot. The wall can further comprise a second sub slot extending orthogonal to the slot in the top face. The wall can further comprise one or more pin-receiving apertures disposed in the slot, one or more pin-receiving apertures disposed in the first sub slot and one or more pin-receiving apertures disposed in the second sub slot. The wall can further comprise a second sub slot extending orthogonal to the slot in the top face and parallel to the first sub slot. The wall can further comprise one or more pin-receiving apertures disposed in the slot, one or more pin-receiving apertures disposed in the first sub slot and one or more pin-receiving apertures disposed in the second sub slot. The wall can further comprise a core disposed in the first masonry block.

A method of manufacturing a wall is disclosed that includes placing a pin in a first block having a front face, a rear face disposed opposite the front face, a first side face disposed between the front face and the rear face, a second side face disposed between the front face and the rear face and opposite the first side face, a top face disposed adjacent to the front face, the rear face, the first side face and the second side face, a bottom face disposed opposite to the top face and adjacent to the front face, the rear face, the first side face and the second side face and wherein the top face includes a slot extending from the first side face to a point between the first side face and the second side face, the slot including a first sub slot extending orthogonal to the slot in the top face and aligning a core of a second block over the pin. The method can further comprise wherein the pin is placed in a pin-receiving apertures. The method can further comprise wherein the pin is placed in one of a pin-receiving aperture disposed in the slot and one or more pin-receiving apertures disposed in the first sub slot.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.”

It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.

Claims

1. A masonry block, comprising: a front face;a rear face disposed opposite the front face;a first side face disposed between the front face and the rear face;a second side face disposed between the front face and the rear face and opposite the first side face;a top face disposed adjacent to the front face, the rear face, the first side face and the second side face;a bottom face disposed opposite to the top face and adjacent to the front face, the rear face, the first side face and the second side face; andwherein the top face includes a slot extending from the first side face to a point between the first side face and the second side face, the slot including a first sub slot extending orthogonal to the slot in the top face.

2. The masonry block of claim 1 further comprising one or more pin-receiving apertures.

3. The masonry block of claim 1 further comprising one or more pin-receiving apertures disposed in the slot and one or more pin-receiving apertures disposed in the first sub slot.

4. The masonry block of claim 1 further comprising a second sub slot extending orthogonal to the slot in the top face.

5. The masonry block of claim 4 further comprising one or more pin-receiving apertures disposed in the slot, one or more pin-receiving apertures disposed in the first sub slot and one or more pin-receiving apertures disposed in the second sub slot.

6. The masonry block of claim 1 further comprising a second sub slot extending orthogonal to the slot in the top face and parallel to the first sub slot.

7. The masonry block of claim 6 further comprising one or more pin-receiving apertures disposed in the slot, one or more pin-receiving apertures disposed in the first sub slot and one or more pin-receiving apertures disposed in the second sub slot.

8. The masonry block of claim 1 further comprising a core disposed in the masonry block.

9. A wall, comprising: a first masonry block having a front face, a rear face disposed opposite the front face, a first side face disposed between the front face and the rear face, a second side face disposed between the front face and the rear face and opposite the first side face, a top face disposed adjacent to the front face, the rear face, the first side face and the second side face, a bottom face disposed opposite to the top face and adjacent to the front face, the rear face, the first side face and the second side face and wherein the top face includes a slot extending from the first side face to a point between the first side face and the second side face, the slot including a first sub slot extending orthogonal to the slot in the top face;a second masonry block disposed on top of the first masonry block and having a core; anda pin disposed in the slot and extending into the core.

10. The wall of claim 9 further comprising one or more pin-receiving apertures in the first masonry block.

11. The wall of claim 9 further comprising one or more pin-receiving apertures disposed in the slot and one or more pin-receiving apertures disposed in the first sub slot.

12. The wall of claim 9 further comprising a second sub slot extending orthogonal to the slot in the top face.

13. The wall of claim 12 further comprising one or more pin-receiving apertures disposed in the slot, one or more pin-receiving apertures disposed in the first sub slot and one or more pin-receiving apertures disposed in the second sub slot.

14. The wall of claim 9 further comprising a second sub slot extending orthogonal to the slot in the top face and parallel to the first sub slot.

15. The wall of claim 14 further comprising one or more pin-receiving apertures disposed in the slot, one or more pin-receiving apertures disposed in the first sub slot and one or more pin-receiving apertures disposed in the second sub slot.

16. The wall of claim 9 further comprising a core disposed in the first masonry block.

17. A method of manufacturing a wall, comprising: placing a pin in a first block having a front face, a rear face disposed opposite the front face, a first side face disposed between the front face and the rear face, a second side face disposed between the front face and the rear face and opposite the first side face, a top face disposed adjacent to the front face, the rear face, the first side face and the second side face, a bottom face disposed opposite to the top face and adjacent to the front face, the rear face, the first side face and the second side face and wherein the top face includes a slot extending from the first side face to a point between the first side face and the second side face, the slot including a first sub slot extending orthogonal to the slot in the top face; andaligning a core of a second block over the pin.

18. The method of claim 17 further wherein the pin is placed in a pin-receiving apertures.

19. The method of claim 17 wherein the pin is placed in one of a pin-receiving aperture disposed in the slot and one or more pin-receiving apertures disposed in the first sub slot.