Patent Application
20240401299
This application is directed to segmented wall and landscaping block systems with improved inter-block coupling. More generally, the application is directed to segmented wall systems, retaining walls and landscaping block systems with lug-type engagement and coupling features.
Segmented wall and landscaping block products are available in a wide variety of materials and styles, adapted for use in retaining walls, partition walls, garden and patio walls, and other landscaping structures. Natural stone, concrete, precast blocks and masonry are commonly used, either alone or in combination with other materials including anchoring and retaining elements, fascia, drainage features, timbers, ties, and other structural components.
Segmented wall systems can be used to construct laid, positioned, and dry-stacked structures without the need for mortar and other binding component. Segmented wall systems can also provide improved structural integrity and durability, combined with a wide range of architectural finishes selected for style, appearance, and other user preferences.
A mold can be used to form the blocks, either singly or multiply in the form of manufacturing modules, for example from dry cast concrete or from aggregate, reinforced fiber or matrix composite materials, combined with cement or another suitable binder. The blocks can be formed as hollow units with internal core structures designed to reduce weight while retaining strength and structural integrity, with a variety of tabs, channels and other elements adapted for anchoring the blocks to a subsurface or reinforced grid, or to one another, for example using locator pins, rods, bars or other mechanical elements. Sidewall liners, stripper shoes and other molding components can also be provided to impart the blocks with textured surfaces and other structural, functional and aesthetic features.
Once completed, the manufacture blocks (or block modules) can be stacked on a pallet or other structure for shipping, and then assembled on location into a segmented wall system or other landscaping structure. Across these applications, there remains a need for additional structural features adapted to improve inter-block coupling during shipment, storage and handling, which are not subject to the limitations of existing prior art designs.
A segmented wall system includes a plurality of blocks forming first and second courses, extending in a longitudinal direction. The blocks have engagement lugs extending from the top or bottom surface; e.g., along the front or rear portions of the block, on opposing sides of the central opening. The lugs of a selected block in the first course can be adapted to engage the openings of one or more blocks in the second course, for example along one or more of the front, rear, and adjacent side surfaces of the openings in an adjacent pair of blocks in the second course, improving structural stability of the assembled wall system. The lugs can also be adapted for stacking in a nested shipping configuration, reducing shipping volume and limiting relative motion of the stacked blocks, for example where the blocks sit flat, and on the lugs, to decrease the risk of damage during shipment, storage and handling.
Depending on application, the wall system can include a plurality of landscaping blocks, each having a front portion, a back portion, and first and second sidewall portions extending between the front portion and the back portion, and an opening having a perimeter defined along the inner surfaces of the front, back and sidewall portions, and a lug process extending from each sidewall portions. First and second courses can be assembled from a number of the landscaping blocks and stacked vertically (on or under) the first course. The lug processes extending from the sidewall portions of a landscaping block in the first course can engage different openings in an adjacent pair of landscaping blocks in the second course. Conversely, the lug processes on adjacent sidewall portions of an adjacent pair of landscaping blocks in the first course can engage the same opening in the same (single) landscaping block in the second course.
Depending on application, the landscaping block can include a front wall portion, a back portion, first and second sidewall portions extending between the front wall portion and the back portion, and an opening defined between the front wall portion, the back portion and the sidewall portions, with the perimeter defined along the corresponding inner surfaces. Lug processes extend from each of the sidewall portions, with beveled surfaces configured to engage different openings in an adjacent pair of similar landscaping blocks, when stacked adjacent (on or under) the landscaping block in a wall system.
Conversely, the beveled surfaces are also configured for the lug processes on adjacent pair of landscaping blocks to engage the same opening of a single such block, when stacked vertically above or below (adjacent) the pair of blocks. For example, the beveled surfaces can be symmetric about the block centerline, and oriented toward the back portion of the landscaping block (and configured to engage the openings in the adjacent pair of landscaping blocks along the inner surfaces of the respective back portions), or oriented toward the front wall portion of the landscaping block (and configured to engage the openings along the inner surfaces of the respective front wall portions).
In some applications, nesting structures are defined along exterior surfaces of the first and second sidewall portions, and adapted to receive the lug processes of additional landscaping blocks stacked in an adjacent layer for shipping or storage. The nesting structures can be adapted to limit lateral motion of the landscaping blocks in the adjacent layer, by engagement with the respective lugs. For example, the nesting structures can be adapted for landscaping blocks in the adjacent layer to have a reversed or rotated orientation, when stacked for shipping or storage. The nesting structures can be adapted for the landscaping blocks in the adjacent layer to have a stacked shipping or storage height that is the same as the installed height of the landscaping block, when assembled into a wall system. Methods of assembling the blocks into a wall system or shipping configuration are also included.
The figures identify elements of the blocks and segmented wall systems using reference numbers and symbols. Not all of the references are repeated for every instance of each element, for example where multiple instances of common elements appear in the same and related drawings, or to improve clarity when describing other, additional features of the drawings, where the common features have already been described, or are understood in the art.
Certain details are set forth below to provide an understanding of the present disclosure. These examples can be applied to practice in various combinations, as understood by those of skill in the art, without necessarily including every detail that is disclosed. The applications described here are provided by way of example, and do not limit the scope of the disclosure, except as defined by the appended claims.
More generally, this disclosure includes exemplary applications of segmented wall systems using a variety of landscaping blocks with lug-type engagement features adapted to improve coupling between adjacent courses of blocks. In some examples, the segmented wall system can be constructed from several vertically stacked courses or layers of such blocks. Each course or layer can extend in a longitudinal (e.g., horizontal) direction, with successive courses extending in a transverse (e.g., vertical) direction to define the face of the wall system.
For example, each course can include a set of blocks positioned side-by-side in a substantially level plane. The number of the blocks in each course can be selected based on the desired length of the wall system in the longitudinal direction, and the respective width of the blocks. The number of courses can be selected based on the desired height of the wall system in the transverse (vertical) direction, and the respective installed height.
Lug-type inter-block engagement processes (or “lugs”) can be formed on the top or bottom surface of each block, so that the lugs on one (e.g., lower) course engage the openings in one or more blocks of an adjacent (e.g., upper) course. In some examples, the horizontal alignment of the blocks between adjacent courses can be offset so that a pair of lugs on a block on the first course engages the openings of two different, adjacent blocks in the second course.
The lugs can be disposed toward the back wall of the block, and adapted to engage one or more of the respective rear and adjacent side surfaces of the openings in the blocks of successive course. The lugs can be disposed toward the front wall of the block, and adapted to engage one or more of the respective front and adjacent side surfaces of the openings. The lugs can also be provided on either the top or bottom surfaces of the blocks, and the upper and lower orientation of the courses can be reversed or rotated, without loss of generality.
In some examples, the blocks include a pair of symmetrical, opposing lugs formed on a top surface of the block sidewalls, extending between the front and back of the block. The front portion can define the front face of the block, for example with an outward-facing textured surface, opposite the back portion. The front, back and sidewall portions define the inner surfaces of the opening; e.g., as disposed about the block center of gravity in the core region.
The lugs can be beveled, rounded, shaped, or otherwise adapted to engage with or conform to the corresponding surfaces of the openings in the adjacent stacked blocks; e.g., along either the rear or front surface, or along the adjacent side surfaces, or a combination thereof.
In some examples, the segmented wall systems can be assembled by vertically stacking a number of horizontally adjacent blocks to form the successive courses. The geometry of the blocks can be selected so that the lugs of a block in the first course can engage the openings in one or more blocks of the second, adjacent course, in which the blocks are successively stacked. When assembled, the wall system can have a generally linear geometry, or any combination of linear, convex and concave curvature.
The degree of curvature, for example, can be determined by the depth of the blocks and the angle of the block sidewalls, so that they do not interfere with those of the horizontally adjacent blocks. The curvature can also be determined by an angle between the adjacent blocks when assembled into a course, so that the lugs of each block are disposed within the cavities of the blocks in the adjacent (e.g., upper or lower) course, and do not interfere with the respective front, back, or sidewall structures.
Suitable wall systems can also utilize reinforced earth techniques, including, but not limited to, geogrid reinforcement, geosynthetic reinforcement, substantially inextensible materials such as steel matrices, and other reinforcement materials. After placement of a course or layer of the wall system, for example, a geogrid reinforcement material can be placed over the installed blocks, before placement of the successive course. The weight of the upper course on the geogrid material sandwiched between two courses can help hold the geogrid material in place, and, conversely, the geogrid material can help hold the blocks in place, in the successive courses. Additional pins, rods, stakes and other mechanical connectors can also be employed, and fill materials can be used help keep the blocks and geogrid material in place.
In these examples, block 100 is formed of a front wall or front portion 112 defining the front face 113 of block 100, and a back wall or rear portion 114 defining the back surface 115, substantially opposed to and parallel with the front face 113. Block sidewalls (or “neck” portions) 116, 118 extend transversely between front and back wall portions 112, 114; e.g., defining a block side angle (A) as measured from a perpendicular to front face 113 (
Blocks 100 can be made of durable, rugged, weather resistant materials selected for strength and structural integrity, including but not limited to precast concrete (e.g., dry cast or wet cast concrete). Other suitable materials include composite materials, polymers, plastics, reinforced fibers, materials, wood, metal, stone and combinations thereof.
One or both of the front and back surfaces 113, 115 of block 100 can be provided with texturing or other surface features TX; e.g., as indicated in
The engagement lugs 120, 122 can be defined in a symmetrical sense about the centerline CL of block 100, extending from the top surface 104 of each block sidewall 116, 118 with a common process height (P). Individual blocks 100 and lugs 120, 122 can have a uniform or common size and shape, for example with a standard or uniform installed vertical height H, as defined between the top and bottom surfaces 104, 106, a common width W, as defined at or across the front face 113, and a common depth D, as defined between the front face 113 and the back surface 115. Alternatively, blocks of different sizes and configurations can be used.
One or more grooves or channel features 125, 126 can be formed in either or both of the block sidewalls 116, 118 during the manufacturing process, for example adjacent to the engagement lugs 120, 122 (channel 125), or spaced from lugs 120, 122 along the top surface 104 (channel 126). As shown in
The width W1 of back surface 115 of block 100 can differ from the width W of the front face 113. For example, the width W1 of the back surface 115 may be less than the width W of the front face 113, in order to facilitate the arrangement of blocks 100 into curved wall systems. The width W2 of opening 130 can be defined at or adjacent the back wall portion 114, and selected to accommodate engagement with the lugs 120, 122 of overlaying blocks 100 when assembled into adjacent courses of a segmented wall system, as described herein.
The front, back and side wall portions 112, 114, 116 and 118 of block 100 extend vertically between the upper or top surface (top) 104 of block 100 and lower or bottom surface (bottom) 106, defining a central cavity or opening 130 in the core region. The center of gravity CG of block 100 may be defined inside the opening 130, for example along the midline or centerline CL at distance D1 from the front face 113, and at height H1 from the bottom surface 106, as shown in
The perimeter of opening 130 extends along the inner surfaces of the front, back and side wall portions 112, 114, 116 and 118 of block 100, respectively, with corresponding inside front, rear, and side surfaces 133, 135, 137 and 139 forming the perimeter of opening 130. The thicknesses T1, T2, T3 and T4 of front wall 112, back wall 114, and side walls 116, 118 may vary, depending the dimensions of opening 130, the depth D and width W, W1 of block 100, and the corresponding structural requirements for assembly of blocks 100 into a segmented wall system, or other structure.
The top and bottom surfaces 104, 106 of block 100 are defined by the corresponding upper and lower surfaces of the front, back and side wall portions 112, 114, 116, 188, extending about the perimeter of opening 130. The top and bottom of block 100 can be formed with flat or complementary (e.g., contoured) surfaces 104, 106, and adapted for close stacking of blocks 100 without gaps between vertically adjacent courses. Surfaces 104, 106 can also be provided with textured features.
In order to couple adjacent courses of blocks 100 together, each block 100 includes one or more lug-type processes or protrusions (“lugs”) 120, 122; e.g., extending from the top surface 104. For example, a pair of engagement lugs 120, 122 can be defined on the respective side wall portions 116, 118 of block 100, adjacent the back wall portion 114, and extending from the top surface 104 with a common process height (P) as shown in
Engagement lugs 120, 122 can be positioned directly adjacent the back wall portion 114 of block 100, approximately horizontally aligned with the rear surface 135 of opening 130, where the back wall 114 meets the respective sidewalls 116, 118. Suitable lugs 120, 122 can also be offset from the rear surface 135 of opening 130, as defined along the respective block sidewall 116, 118. This configuration can provide a staggered or inclined wall system 150 with selected setback distance (SB) and setback angle (SA) between successive courses; e.g., as further illustrated according to
Lugs 120, 122 can be provided with a corner bevel B1 or similar contour oriented toward the back portion 114 of block 100, and adapted to interface with or engage along the rear surface 135 of the opening 130 in a vertically adjacent block 100, when blocks 100 are stacked on top of one another in a segmented wall system. Corner bevels B1 can also engage one or more side surfaces, 137, 139 of the respective opening 130. In some examples, the bevels B1 on lugs 120, 122 can be symmetric, for example as reflected about the block centerline CL as illustrated in
The rearward-facing and outside surfaces of lugs 120, 122 can be shaped to conform to the rear, side or corner geometry of the openings 130 in one or more overlaying blocks 100, as defined along one or more of the corresponding surfaces 135, 137 and 139, respectively. For example, lugs 120, 122 can be provided with a rounded corner surface or corner bevel B1 along the back and side surfaces, as shown in
The lug connections can be formed via contact between a pair of lugs 120, 122 formed on the (as-installed) top surface 104 of one block 100 in a lower course or layer, with the rear surface 135 of the opening 130 in one or more blocks 100 of an upper course. In some examples, the horizontal alignment of blocks 100 between the two courses can be offset, so that one lug 120 on a block 100 in the lower course can engage along the rear surface 135 of the opening 130 in a first block 100 of the upper course, and a second lug 122 from the same block 100 in the lower course can engage along the rear surface 135 of the opening 130 in a second block 100 of the upper course, horizontally adjacent to the first block.
While
As shown in
In
In some examples, the geometry of wall system 150 can accommodate the engagement of a pair of lugs 120, 122 on one block 100 in a lower course 160 with the rear surfaces 135 of openings 130 in two adjacent blocks 100 in an upper course 162. The interfaces 170 between abutting blocks 100 can thus be offset or staggered in the adjacent courses 160, 162, for example with the interface 170 between adjacent blocks 100 in the upper course 162 approximately bisecting the corresponding block 100 in lower course 160, as shown in
The arrangement of wall system 150 with inter-layer structural couplings provided by engagement of lugs 120, 122 in the openings 130 of adjacent stacked blocks 100 increases stability by adding an interlocking structure between blocks 100 in consecutive courses 160, 162. The openings 130 in blocks 100 can also be packed with a fill material (FF); e.g., as shown in
In some applications, wall system 150 can also utilize reinforced earth techniques such as geogrid reinforcement, geosynthetic reinforcement, inextensible materials such as steel rods or a steel matrix, or other reinforcement material (GD) as shown in
The curvature may uniform (R1=R2) or may vary (R1≠R2), with each portion of wall system 150 defining a respective wall angle accordingly. A maximum wall angle, in turn, can be defined by the gap distance (G) between the outside edges of the lugs 120, 122 on adjacent blocks 100 in the upper or lower course 160, 162; e.g., as shown in
For example, the maximum (concave) block wall angle can be defined so that the gap between the outside edges of lugs 120, 122 on adjacent blocks 100 in lower course 160 is less than or equal to the width W2 along the rear surface 135 of the opening 130 in the overlaying block 100, in the upper course 162. Thus, the lugs 120, 122 on one block 100 in the lower course 160 can be engaged within the openings 130 of two adjacent overlaying blocks 100, in the upper course 162. Conversely, the lugs 122, 120 on two adjacent blocks 100 in the lower course 160 can be engaged within the same opening 130 of the same overlaying block 100, in the upper course 162. This arrangement provides cross-coupling of adjacent blocks 100 in successive courses 160, 162, substantially improving the strength, rigidity and structural integrity of wall system 150.
The wall systems 150 in
In these examples, block 200 is formed of a front wall portion 212 defining the front face 213, and a back wall or rear portion 214 defining the back surface 215, substantially opposed to and parallel with the front face 213. Block sidewalls (“leg” or “neck” portions) 216, 218 extend transversely between front and back walls 212, 214.
Blocks 200 can be made of durable rugged, weather resistant materials selected for structural integrity, including but not limited to precast concrete (e.g., dry cast or wet cast concrete). Other suitable materials include polymers, plastics and reinforced fibers, composite materials, wood, metal and stone, and combinations thereof.
As shown in
The width W1 of back surface 215 may vary, and may differ from the width W of the front face 213. For example, the width W1 of the back surface 215 may be less than the width W of the front face 213, in order to facilitate the arrangement of blocks 200 into curved wall structures. The width W2 of opening 230 can also vary, for example as defined at or adjacent the back face 215, in order to engage the lugs 220, 222 of underlaying blocks 200 when assembled into adjacent courses of a segmented wall system, as described herein.
In some examples, blocks 200 have a standard or uniform installed vertical height H, a common width W, and a common depth D. The blocks 200 can be made of a rugged, weather resistant material, such as precast concrete (e.g., dry cast or wet cast). Other suitable materials include plastic, reinforced fibers, wood, metal and stone.
One or more grooves or channel features 225 can be formed in either or both of the block sidewalls 216, 218; e.g., along the top surface 204, adjacent lugs 220, 222. As shown in FIG. 6B, for example, channels 225 extend transversely across each block sidewall 216, 218, from the central opening 230 to the exterior of block 200. The depth of channels 225 may be the same or may vary, as described herein.
One or both of the front and back surfaces 213, 215 of block 200 can be provided with texturing or other surface features TX; e.g., as indicated in
Blocks 200 can include at least one cavity, aperture or opening 230 formed between the front wall portion 212 (e.g., defining the front surface 233 of opening 230), and the back portion 214 (defining the rear surface 235 of opening 230). Sidewall portions 216, 218 of block 200 extend between the front and back wall portions 212, 214, defining the side surfaces 237, 239 of opening 230, on the opposing sides of the block 200.
Similarly, the outer surfaces of sidewalls 216, 218 can define the outside surfaces of block 200. The top and bottom surfaces 204, 206 of block 200 can be formed with complementary flat or contoured surfaces to facilitate stacking of blocks 200 on top of one another in adjacent courses of a segmented wall system, as described herein.
In order to connect courses or layers of blocks 200 together, each block 200 can include a pair of engagement lugs 220, 222; e.g., extending from the top surface 204 of block 200. The lugs 220, 222 protruding from the top surface 204 of block 200 can be horizontally aligned with the rear surface 235 of opening 230, and positioned on the block sidewalls 216, 218 proximate the back corner of block 200, where the sidewalls 216, 218 meet back wall 214.
The pair of lugs 220, 222 can be configured to interface with the rear surface 235 of the opening 230 of one or more additional blocks 200, when stacked on top of the first block 200. For example, lugs 220, 222 can be provided with a corner bevel B1 defined by angled or rounded surfaces on the back and side of each lug 220, 222, as shown in
In some examples, a pair of symmetrical lugs 220, 222 can be provided, for example as reflected about the block centerline CL. Furthermore, the pair of lugs 220, 222 can be flush with the rear surface 235 of the opening 230 or offset along the respective block sidewall 216, 218. This configuration can provide a staggered incline with a selected setback distance (SB) and setback angle (SA) between blocks 200; e.g., when blocks 200 are assembled into successive courses 260, 262 of a wall system 250 according to
The lug connections can be formed via engagement of a pair of lugs 220, 222 formed on the top surface 204 of block 200, as installed on a lower course or layer, with the rear surface 235 of the openings 230 in one or more blocks 200 on an upper course. In some examples, the horizontal alignment of blocks 200 between courses can be offset so that one lug from a block 200 on the lower course can interface with the rear surface of the opening of a first block 200 on the upper course, and a second lug from the same block 200 on the lower course can interface with the rear surface 235 of the opening 230 of a second block 200, adjacent the first block along the upper course.
Conversely, the lugs 220, 222 on adjacent blocks in a lower course 260 can be engaged within the opening 230 in a single upper course block 200, when the upper-course block 200 is staggered over the adjacent lower-course blocks 200. Depending on application, the upper and lower surface of the blocks can also be interchanged, along with the upper and lower designations of the courses 260262, and lugs 220, 222 can be adapted for engagement along either the front or rear surfaces of the corresponding cavities 230, as further described herein.
As shown in
In
In some examples, the geometry of wall system 250 can accommodate the engagement of lugs 220, 222 on one block 200 in the lower (or bottom) course 260 with the rear surfaces 235 of openings 230 in two adjacent blocks 200 in the upper course 262. The interfaces 270 can thus be staggered, with each upper-course block 200 overlaying a different portion of respective the lower block 200, and the interface 270 between adjacent blocks 200 in the upper course 262 approximately bisecting the corresponding block 200 in lower course 260, as shown in
Lugs 220, 222 add stability to the segmented wall system 250 by providing additional coupling between adjacent courses 260, 262, as described above for wall system 150. Similarly, the openings 230 in blocks 200 can be packed with a fill material (FF), for example as shown in
The segmented wall systems 250 in
Blocks 300 can also include one or more apertures, cavities or openings 330, for example disposed about the center of gravity CG and defined between the front wall 312, defining the front surface 333 of opening 330, and the back portion 314, defining the rear surface 335. Block sidewalls 316, 318 extend between the front and back portions 312, 314, with inner surfaces defining the corresponding inside surfaces 337, 339 of opening 330, on the opposing sides (e.g., left and right) of block 300.
One or more grooves or channel features 325, 326 can be formed in either or both block sidewalls 316, 318 during the manufacturing process; e.g., adjacent lugs 320, 322 (channel 325), or spaced from lugs 320, 322 along top surface 304 (channel 326). As shown in
The outer surfaces of block sidewalls 316, 318 define the exterior surfaces of block 300. The top and bottom surfaces 304, 306 of each block 300 can be provided with complementary flat or contoured surfaces to facilitate stacking, as described herein.
Suitable base blocks 300 can also include a block coupling 380 adapted for coupling to a tail unit 400 when installed in a segmented wall system. For example, one or more blocks 300 can be connected to tail units 400 using a vertical dovetail block coupling 380 extending from the back portion 314 of block 300. In these examples, block coupling 380 extends between the top and bottom surfaces 304, 306 on the back portion 314 of block 300, opposite the front face 313 as shown in
In order to connect the courses of blocks 300 together when installed in a segmented wall system, each block 300 can include one or more engagement lugs 320, 322; e.g., a pair of lugs 320, 322 extending from the top surface 304 of block 300 at a common process height (P). The lugs 320, 322 can be horizontally-aligned with the rear surface 335 of opening 330, positioned on the block sidewalls 316, 318 adjacent the back portion 314, or where the back portion 314 meets the block sidewalls 316, 318.
Lugs 320, 322 can be configured to interface with the rear surface 335 of the openings 330 of one or more upper-course blocks 300, stacked on top of the adjacent lower-course blocks 300. Lugs 320, 322 can also be aligned with the rear surface 335 of the opening 330, or offset from the rear surface 335 along the respective block sidewall 316, 318. For example, the offset can be selected to produce a staggered incline with a selected setback distance (SB) between successive courses of blocks 300, extending at a corresponding setback angle (SA) when assembled into a wall system 350 according to
In some examples, lugs 320, 322 are symmetrical; e.g., as reflected about the common centerline CL of block 300. The rear-facing portions of lugs 320, 322 can be shaped to conform to the corner surface of openings 330 in the upper-course blocks 300, when overlaying one or more lower-course blocks. Lugs 320, 322 can also be provided with a beveled, contoured or rounded shape adapted to interface with the corner geometry defined by the rear surface 335 and adjacent side surfaces 337, 339 of the opening 330 in the upper-course blocks 330.
The lug connections can be formed via contact between the pair of lugs 320, 322 formed on the (as-installed) top surface 304 of block 300 on a lower course or layer with the rear surface 335 of the opening 330 in one or more blocks 300 of an upper course. In some examples, the horizontal alignment of blocks 300 can be offset in successive courses so that one lug 320 on a block 300 in the lower course engages the opening 330 of a first block 300 in the upper course, and a second lug on the same block 300 in the lower course engages the opening 330 of a second block 300, adjacent the first block 300 in the upper course.
Conversely, the lugs 320, 322 on adjacent blocks 300 in the lower course can engage the same opening 330 of the same block 300 in the upper course. This cross-coupling further improves the structural stability of the assembled wall system 350, as described herein.
For example, tail unit 400 can include a front portion 412 defining a first (front) end having a complementary coupling 485, which is configured to couple to a dovetail coupling 380 on the back end of the block 300, extending along a common centerline CL. Similarly, the rear wall or back portion 414 of tail unit 400 can define a second opposing (back) end, with a coupling 480 similar to the corresponding (e.g., dovetail) coupling 380 on base block 300.
Base blocks 300 and tail units 400 can be made of a rugged, weather resistant material, including precast concrete (e.g., dry cast or wet cast), composite and polymer materials, reinforced fibers, wood, metal, stone, and combinations thereof. The front portion 412 and back portion 414 of tail unit 400 can be connected by one or more (e.g., left and right) sidewalls 416, 418. The front face 313 of block 300 can be provided with texturing or other surface features TX; e.g., as indicated in
The front portion 412 and back portion 414 of tail unit 400 can also include lateral extensions or “wings” 440, 445; e.g., as configured to couple with similar structures on tail units 400 in adjacent layers or courses. For example, tail units 400 can be formed with two lateral sidewall portions 416, 418 that define an opening (aperture or cavity) 430 in the core region of tail unit 400, between the front portion 412 and the back portion 414, with wing portions 440, 445 extending laterally from one or both of the front and back portions 412, 414, respectively.
The outer surfaces of the sidewalls 416, 418 can define the exterior sides of tail unit 400. The top and bottom surfaces 404, 406 of tail unit 400 can be formed as a flat surfaces to facilitate stacking of similar tail units 400 on top of one another, or the top and bottom surfaces 404, 406 can be formed with complementary, contoured surfaces.
Base blocks 300 can each have a first uniform size and shape, and the tail units 400 can each have a second uniform size and shape that is different from that of the blocks 300. In typical examples, base blocks 300 and tail units 400 may have the same vertical height H, as installed in wall system.
The width W3 of tail unit 400 can be the same or similar to that of the base block 300 in order to facilitate coupling of the wing portions 440, 445, or the width W3 of tail unit 400 may be less than that of the block 300. Similarly, the length LT of tail unit 400 can be greater than the face-to-face depth D of base blocks 300, or the length LT of tail unit 400 may be the same or less than the base block depth D.
In some examples, the opposing sidewalls 416, 418 of the tail unit 400 can have a non-parallel relationship defining a block side angle from the front portion to the rear portion; e.g., where the distance between opposing sidewalls 416, 418 is greater toward the front portion 412 of tail unit 400, and less toward the back portion 424. In some examples, the opposing sidewalls 416, 418 may merge together at or near the back end tail unit 400, defining the back portion 424 at the intersection thereof.
The front portion of tail unit 400 can be provided with a complementary coupling 485, which is adapted to engage either the block coupling 380 on base block 300 or a similar coupling 480 on the back of another tail unit 400. For example, the couplings 380, 480 can be configured as female dovetail structures extending from the back portion 314 of block 300 and the back of tail unit 400, respectively, each of which is adapted to engage the complementary (e.g., male dovetail) coupling 485 on the front of tail unit 400.
The complementary coupling 485 can thus be configured to couple the front end of a tail unit 400 to either the back end of a base block 300, or another tail unit 400. The complementary coupling 485 can extend for substantially the entire height of the respective block 300, 400, or the coupling 485 may be reduced in height for structural or assembly purposes.
In particular examples, block coupling 380 is configured as a male dovetail structure extending over more than half of the width W1 of the back portion 314 of the block 300. While
As shown in
In
In wall system 350, one or more tail units 400 can be installed behind some or all of the base blocks 300. The geometry of wall system 350 can still accommodate the engagement of pairs of lugs 320, 322 on a block 300 in lower course 360 with the rear surfaces 335 of openings 330 in adjacent blocks 300 in upper course 362. The interfaces 370 between abutting blocks 300 can be offset or staggered in adjacent courses, similarly to wall systems 150 and 250, as described above, and as further illustrated in
In the corner region of wall system 350, some tail units 400 may be omitted as shown, depending on the space available between blocks. Outside the corner region, tail units 400 can be installed behind some or all of the base blocks 300, extending in either or both directions. The openings 350 in blocks 300 and 400 can also be packed with fill material (FF), for example as shown in
The segmented wall systems 350 in
Blocks 100 can be made of durable, rugged, weather resistant materials selected for strength and structural integrity, and with similar physical features according to other blocks 100, 200, 300, 500 and 600, as described herein. The width (W, W1), depth (D, D2), and height (H, H1) dimensions may vary, depending on application.
As shown in
Engagement lugs 120, 122 are defined on the block sidewalls 116, 118, extending upward from the top surface 104, opposite the bottom surface 106. As shown in
One or more grooves or channel features 125 can be formed in either or both of the block sidewalls 116, 118 during the manufacturing process, for example adjacent to the engagement lugs 120, 122, or spaced along the top surface 104. The beveled back surfaces of lugs 120, 122 can also be offset from the back wall portion 114 of block 100, e.g., at a selected distance (OF) as shown in
Lugs 120, 122 are adapted to engage one or more of the rear surface 135 and adjacent side surfaces 137, 139 of the opening 130 in one or more adjacent blocks 100, for example in a pair of horizontally adjacent blocks 100 in an upper course of a segmented wall system, when arranged on top of the block 100 in a vertically adjacent lower course, as shown in
Adjacent blocks 100 abut at interfaces 170. A fill material (FF) can also be provided in the openings 130 of one or more of the blocks 100, and a geogrid material (GD) can be installed between courses 160, 162, as described herein.
Engagement lugs 120, 122 on adjacent blocks 100 are separated by a gap (G), which is defined by the block side angle and block depth (see
The radius of curvature may vary. For example, an inside radius of curvature (
Suitable wall systems 150 can be formed with any number of courses 160, 162, each having any number of blocks 100. The blocks 100 can be arranged to provide sections of wall system 150 with linear or nonlinear geometry, straight segments, corners, convex or concave curvature, or any combination thereof. Wall systems 150 can also be assembled from any combination of landscaping blocks, tail units and corner blocks described herein, in any suitable geometry.
As shown in
Blocks 500 can be made of durable, rugged, weather resistant materials selected for strength and structural integrity, and with similar physical features according to other blocks 100, 200, 300, 500 and 600, as described herein. The width (W, W1), depth (D, D2), and height (H, H1) dimensions may vary, depending on application.
As shown in
Engagement lugs 520, 522 are defined on the sidewalls or side portions 516, 518 of block 500, extending upward from the top surface 504, opposite the bottom surface 506. One or more central openings or cavities 530 can be defined between the front, back and opposing side wall portions 512, 514, 516, 518 of block 500; e.g., disposed about the center of gravity CG, with the perimeter of opening 530 defined along the corresponding inside front, rear, and sidewall surfaces 533, 535, 537 and 539.
Lugs 520, 522 can be provided with a symmetric bevel B2 along the back surface, as reflected about block centerline CL. Lugs 520, 522 can have substantially parallel side surfaces extending flush to the outer surfaces of block sidewalls 516, 518, and along the opposing inner surfaces 537, 539 of opening 530. One or more grooves or channel features 526 can be formed in either or both of the block sidewalls 516, 518 during the manufacturing process, for example spaced from the engagement lugs 520, 522 along the top surface 504.
The beveled back surfaces of lugs 520, 522 can be offset from the back wall portion 514 of block 500, for example by a selected distance (OF) along the respective block sidewalls 516, 518 as shown in
As shown in
The reverse angle of the front portions of the block sidewalls 516, 518 can be adapted to form nesting structures 528 along the exterior surface of the front portions of block sidewalls 516, 518, and along the adjacent (rear) surface of front wall extension 540 (or along either or both surfaces), as shown in
Adjacent blocks 500 abut at interfaces 570. A fill material (FF) can be provided in the openings 530 of one or more of the blocks 500, and a geogrid material (GD) can be installed between courses 560, 562, for example to strengthen the assembled wall system 550 and improve drainage.
Engagement lugs 520, 522 on adjacent blocks 500 are separated by a gap (G), which is defined by the block side angle and block depth (see
The radius of curvature may vary according to maximum convex and concave block wall angles, as described herein. Wall systems 550 can also be assembled from any combination of landscaping blocks, tail units and corner blocks described herein, with linear or nonlinear geometry, straight segments, corners, convex or concave curvature, or any combination thereof.
As shown in
The surfaces of the lugs 520, 522 and the angles of the corresponding sidewall sections of the blocks 500 can be further adapted for the lugs 520, 522 to engage with the exterior sidewalls and adjacent surfaces of an overlaying, stacked block 500 (compare, e.g.,
Blocks 600 can be made of durable, rugged, weather resistant materials selected for strength and structural integrity, and with similar physical features according to other blocks 100, 200, 300, 500 and 600, as described herein. The width, depth, and height (H) may vary, depending on application.
As shown in
In particular examples, engagement lugs 620, 622 are disposed on the outer surfaces of block sidewalls 616, 618, extending upward from the top surface 604 of block 600 adjacent the back portion 614. Lateral extensions 640 can be defined on the front wall portion 612 of block 600, extending outward of the connections to block sidewalls 616, 618. Transverse processes 646 can be defined on the back portion 614, for example extending rearward (transverse to back wall portion 614) as shown in
Engagement lugs 620, 622 are defined on outer edges of block sidewalls 616, 618, extending upward from the top surface 604, adjacent the back portion 614. Lugs 620, 622 can be provided with an outside bevel B3; e.g., oriented toward the back portion 614 of block 600 and extending symmetrically along the back surface and outside edges of lugs 620, 622, as reflected about block centerline CL.
Depending on application, the inside edges of lugs 620, 622 can be defined along the adjacent flat structures 621, 623, disposed on the inside edges of block sidewalls 616, 618, adjacent opening 630 and back portion 614. For example, flats 621, 623 can be formed onto block sidewalls 616, 618 by a double-action head or by machining, or a combination thereof, so that flats 621, 623 have approximately the same height (or are approximately even with) the top surface 604 of block 600.
One or more grooves or channel features 625 can also be formed in block sidewalls 616, 618, for example adjacent the front edge of engagement lugs 620, 622. Bevel B3 can be adapted to engage one or more rear or side surfaces 635, 637 and 639 of the openings 630 in one or more vertically adjacent blocks 600, for example when stacked in successive courses of a segmented wall system 650 as further illustrated in
Nesting structures 628 can be formed along the exterior surfaces of the front portions of block sidewalls 616, 618, extending to or along the adjacent (rear) surface of front wall extension 640 (or along either or both surfaces), as shown in
Adjacent blocks 600 abut at interfaces 670. A fill material (FF) can be provided in the openings 630 of one or more of the blocks 600, and a geogrid material (GD) can be installed between courses 660, 662, as described herein.
The engagement lugs 620, 622 on adjacent blocks 600 are separated by a gap (G), as defined by the block side angle and depth (see e.g.
As shown in
The beveled surfaces of lugs 620, 622 and the angles of the corresponding sidewall sections of each block 600 can be further adapted for the lugs 620, 622 to engage with the exterior sidewall and adjacent surfaces forming the nesting structures 628 in the overlaying, stacked layer 692 of blocks 600 (compare, e.g.,
Blocks 500 can be made of durable, rugged, weather resistant materials selected for strength and structural integrity, and with similar physical features according to other blocks 100, 200, 300, 500 and 600, as described herein. The width, depth, and height (H) may vary, depending on application.
As shown in
Lateral extensions or processes 540, 545 can be defined on the front and back wall portions 512, 514 of block 500, respectively, extending outward of the connections to the block sidewalls 516, 518. One or more central openings or cavities 530 can be defined between the front, back and opposing side walls 512, 514, 516, 518; e.g., disposed about the center of gravity CG, with the perimeter of opening 530 defined by the corresponding inside front, rear, and sidewall surfaces 533, 535, 537 and 539.
A block side angle (A) can be defined along the rear section of sidewalls 516, 518. Nesting structures 528 can be defined along the exterior surface of the front portions of block sidewalls 516, 518, and along the adjacent (rear) surface of front wall extension 540 (or along either or both surfaces), as shown in
Adjacent blocks 500 abut at interfaces 570. A fill material (FF) can be provided in the openings 530 of one or more of the blocks 500, and a geogrid material (GD) can be provided between courses 560, 562.
Contact areas 575 between blocks 500 in adjacent courses 560, 562 are shown with dashed lines. Contact areas 575 indicate the vertical loading path when blocks 500 are assembled into wall system 500, and vary accordingly for the other wall systems and block elements described herein, depending on individual block geometry and wall system configuration.
Engagement lugs 520, 522 on adjacent blocks 500 are separated by a gap (G), as defined by the block side angle and block depth (see e.g.
Alternatively,
Blocks 500 can be arranged in a reversed face-to-face orientation so that the lugs 520, 522 of blocks 500 in successive layers 592 are disposed within the nesting structures 528 of blocks 500 in an adjacent layer 592. The orientations of blocks 500 in adjacent layers 592 can be reversed or rotated; e.g., by 180 degrees. The surfaces of the lugs 520, 522 can be further adapted to engage along the exterior sidewall and adjacent surfaces forming the nesting structures 528 of blocks 500 in an overlaying, stacked layer 592, reducing the height of the stacked blocks and limiting the range of relative motion to reduce the risk of damage to blocks 500 during shipment, storage and handling.
One or more grooves or channel features 526 can be formed in either or both block sidewalls 516, 518 during the manufacturing process; e.g., spaced from lugs 520, 522 along the top surface 504 of block 500. More generally, the shape and location of manufacturing features such as channels 526 may vary, along with the precise shape, beveling, and offset (OF) of the engagement lugs 520, 522 and other physical features of block 500, as described herein, and as known in the art.
Blocks 500 can be made of durable, rugged, weather resistant materials selected for strength and structural integrity, and with similar physical features according to other blocks 100, 200, 300, 500 and 600, as described herein. The width, depth, and height (H) may vary, depending on application.
One or more central openings or cavities 530 can be defined between the front, back and opposing side walls 512, 514, 516, 518; e.g., disposed about the center of gravity CG, with the perimeter of opening 530 defined by the corresponding inside front, rear, and sidewall surfaces 533, 535, 537 and 539. One or more grooves or channel features 525, 526 can be formed in either or both block sidewalls 516, 518 during the manufacturing process; e.g., adjacent lugs 520, 522 (channel 525), or spaced from lugs 520, 522 along the top surface 504 (channel 526).
In particular examples, inter-block engagement processes (lugs) 520, 522 can be disposed along the front sections of block sidewalls 516, 518, extending from the first (e.g., top) surface 504 of block 500 adjacent to or offset (OF) from the front wall portion 512. Lugs 520, 522 can further be provided with a front bevel B4; e.g., with parallel sides extending flush with the respective block sidewalls, generally similar to those or parallel bevel B2, and with a bevel provided on the front surfaces of lugs 520, 522. Front bevel B4 can thus be oriented toward the front wall portion 512 of block 500, and adapted for engagement along the front surfaces 533 of the openings 530 in similar blocks 500, when vertically stacked upon one another in a segmented wall system 550.
As illustrated by these examples, the top and bottom surfaces 504 and 506 of block 500 may be considered arbitrarily, and can be interchanged without loss of generality. In addition, lugs 520, 522 can be oriented toward the front or back of block 500, and blocks 500 can be inverted when assembled into a segmented wall system 550, as further illustrated in
Similarly, nesting structures 528 can be formed along the exterior surfaces of either the front or rear portions of block sidewalls 516, 518; e.g., extending to or along the adjacent (front) surface of rear wall extension 545 (or along either or both surfaces), as shown in
Adjacent blocks 500 abut at interfaces 570. A fill material (FF) can be provided in the openings 530 of one or more of the blocks 500, and a geogrid material (GD) can be provided between courses 560, 562.
The engagement lugs 520, 522 on adjacent blocks 500 are separated by a gap (G), which is defined by the block side angle and block depth. In this “inverted” configuration, the gap can be selected for lugs 520, 522 of a block 500 in an upper course 562 to engage the front portions of the openings 530 in one or more blocks 500 of an adjacent lower course 560. For forward-facing lugs 520, 522, the beveled surfaces can be adapted to engage along the front or adjacent side surfaces of the openings 530 in one or more lower-course blocks 500, as further illustrated in
As shown in
Depending on block spacing, the lugs on a selected block 500 in an upper course 562 can be engaged in the openings 530 of adjacent blocks 500 in a lower course 560. For example, the front bevel on the lugs can be adapted to engage along the front surfaces of the respective openings 530. Conversely, the lugs on adjacent blocks 500 in upper course 562 can be engaged in the opening 530 of the same block 500 in lower course 560.
Blocks 500 can thus be engaged in a complementary fashion with respect to rearward-oriented lug configurations. The vertical orientation of blocks 500 and courses 560, 562 can also be reversed, without loss of generality.
The forward-facing lugs 520, 522 can be adapted to engage the corresponding nesting structures 528 defined along the exterior surfaces of the rear sidewall sections of overlaying, stacked blocks 500, as shown in
Alternatively, rear-facing lugs 520, 522 can be adapted to engage the corresponding nesting structures 528 defined along the exterior surfaces of the forward sidewall sections of the overlaying stacked blocks 500, as further illustrated in
If lugs 520, 522 are oriented down, for example, the pallet 595 can be adapted to receive the lugs on the blocks 500 of the lowest layer 592, so that the blocks 500 still rest on the front, back and sidewall portions. The adjacent layers 592 of blocks 500 can thus be considered to be stacked above or below one another, depending on preference.
In either case the nesting capability of the blocks 500 reduces the height of the shipping layout 590 to the installed height (H), while improving structural stability, and limiting the range of relative motion for the blocks 500 in each adjacent layer 592. This compares to an un-nested configuration, or without nesting capability, where the stacked layer height would be (H+P); that is, the installed height (H), plus the lug process height (P). The nested configuration also substantially reduces the risk of damage to lugs 520, 520 and the other structural components of blocks 500 during shipment, storage and handling.
Blocks 500 can be made of durable, rugged, weather resistant materials selected for strength and structural integrity, and with similar physical features according to other blocks 100, 200, 300, 500 and 600, as described herein. The width, depth, and height (H) may vary, depending on application.
One or more central openings or cavities 530 can be defined between the front, back and opposing side walls 512, 514, 516, 518; e.g., disposed about the center of gravity CG, with the perimeter of opening 530 defined by the corresponding inside front, rear, and sidewall surfaces 533, 535, 537 and 539. One or more grooves or channel features 525 can be formed in either or both block sidewalls 516, 518 during the manufacturing process; e.g., adjacent lugs 520, 522, or spaced from lugs 520, 522 along the top surface 504.
In particular examples, inter-block engagement processes (lugs) 520, 522 can be disposed along the back sections of block sidewalls 516, 518, extending from the first (e.g., top) surface 504 of block 500 adjacent to or offset (OF) from the back portion 514. Lugs 520, 522 can further be provided with a symmetrical bevel B5; e.g., with parallel sides extending flush with the respective block sidewalls 516, 518, generally similar to those of parallel bevel B2, and with bevels provided on the front and rear surfaces of lugs 520, 522. Symmetric bevel B5 can be oriented toward the front or back wall portion 512, 514 of block 500, and adapted for engagement along the front surface 533 of the openings 530 in similar blocks 500, when vertically stacked upon one another in a segmented wall system 550.
As shown in
Nesting structures 528 can be formed along the exterior surfaces of either the front or rear portions of block sidewalls 516, 518; e.g., extending to or along the adjacent (back) surface of front wall extension 540, as shown in
Adjacent blocks 500 abut at interfaces 570. A fill material (FF) can be provided in the openings 530 of one or more of the blocks 500, and a geogrid material (GD) can be provided between courses 560, 562.
The engagement lugs 520, 522 on adjacent blocks 500 are separated by a gap (G), which is defined by the block side angle and block depth. The gap can be selected for lugs 520, 522 of a block 500 in a lower or upper course 560, 562 to engage the perimeters of the openings 530 in one or more blocks 500 of an adjacent upper or lower course 562, 560. For rear-facing lugs 520, 522, the beveled surfaces can be adapted to engage along the rear surface and adjacent side surfaces of the openings 530 in one or more vertically adjacent, stacked blocks 500.
As illustrated in
Depending on block spacing, the lugs on a selected block 500 in a lower course 560 can be engaged in the openings 530 of adjacent blocks 500 in an upper course 562. For example, the symmetric bevel on the lugs can be adapted to engage along one or more of the rear and adjacent side surfaces of the respective openings 530. Conversely, the lugs on adjacent blocks 500 in lower course 560 can be engaged in the opening 530 of the same block 500 in upper course 562.
Blocks 500 can thus be engaged in a complementary fashion with either front or rear-oriented lug configurations. The vertical orientation of blocks 500 and courses 560, 562 can also be reversed, without loss of generality.
As illustrated in
Depending on application and block configuration, the adjacent layers 592 of blocks 500 can thus optionally be considered to be stacked either above or below one another, depending on preference. In either case the height of the shipping layout 590 can be reduced (e.g., to the installed height), while improving structural stability, and limiting the range of relative motion for the blocks 500 in each adjacent layer 592, further reducing the risk of damage to blocks 500 during shipment, storage and handling.
In various exemplary applications, a segmented wall system comprises a first course extending in a first direction and comprising a first block; e.g., where the first block has a pair of lug processes extending above a top surface of opposing sidewall portions of the first block. A second course can be stacked on the first course; e.g., where the second course comprises a second block having an aperture formed through a center of the second block, and where a first one of the pair of lug processes is configured to engage a rear surface of the aperture of the second block, when installed.
The segmented wall system can have a third block with an aperture formed through a center thereof; e.g., where a second one of the pair of lug processes of the first block is configured to engage a rear surface of the aperture of the third block, when installed. Each of the pair of lug processes of the first block can include a rounded inside, rear corner having a radius that matches a radius of a rear corner of the aperture of the second block.
The first block can include an aperture formed through a center thereof; e.g., where each of the pair of lug processes are positioned forward of the rear surface of the aperture of the first block, on the top surface of the opposing sidewall portions. The each of pair of lug processes can has a flat top surface. One or more of the blocks can include a groove across the top surface of each of the opposing sidewall portion; e.g., forward of the pair of lug processes.
In any of these applications the blocks can include a front portion, a rear portion, and two opposing sidewall portions extending between the front portion and the rear portion to form an aperture extending from a top surface to a bottom surface. A pair of lug processes can extend above a top surface of the opposing sidewall portions; e.g., forward of a rear surface of the aperture.
A first one of the pair of lug connections can be configured to engage a rear surface of an aperture of another block stacked thereon. A second one of the pair of lug processes can be configured to engage a rear surface of an aperture of a second block stacked thereon.
Each of the pair of lug processes of the first block can include a rounded inside, rear corner having a radius that matches a radius of a rear corner of the aperture of the second block, or the sides of the lugs can be parallel, and flush with one or more of the sidewall surfaces. Each of the pair of lug processes can have a flat top surface. A groove can be provided across the top surface of each of the opposing sidewall portions; e.g., forward of the pair of lug processes.
Additional exemplary applications include any block described here, any tail block or tail unit described here, or any block system or apparatus. Methods of manufacturing, shipping and assembling the block systems and also included.
Although this description includes specific examples and embodiments, the scope of the disclosure also includes modifications and equivalents thereof, as understood by those of skill in the art. The disclosed structures, functions and features can also be combined with or substituted for one another, without limit to the scope of invention, as defined by the recited language of the claims.
This application claims priority to U.S. Provisional Patent Application Ser. No. 63/505,625, filed Jun. 1, 2023, entitled “Segmented Wall Systems having Lug Connections,” which is incorporated by reference herein, in the entirety and for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 63505625 | Jun 2023 | US |
