FIELD
The present invention relates to blocks, such as concrete blocks, for constructing structures, such as retaining walls, free-standing walls, and columns.
BACKGROUND
Natural stone blocks cut from quarries have been used for a number of years to assemble walls of various types, including ornamental walls for landscaping purposes. Natural blocks have unique sizes, differences in shape and differences in appearance. However, construction of walls using such blocks requires significant skill to match, align, and place blocks so that the wall is erected with substantially uniform courses. While such walls provide an attractive ornamental appearance, the cost of quarried stone and the labor to assemble the stone blocks are generally cost prohibitive for most applications.
An attractive, low-cost alternative to natural stone blocks is molded concrete blocks. In fact, there are several, perhaps hundreds, of utility and design patents which relate to molded blocks and/or retaining walls made from such blocks. Most prior art walls, however, are constructed from dimensionally identical blocks which can only be positioned in one orientation within the wall. Thus, a wall made from molded or cast blocks does not have the same random and natural appearance of a wall made from natural stone blocks.
Accordingly, there is a need for new and improved molded blocks and block systems and methods for constructing walls that have a more natural appearance than walls constructed using molded blocks, block systems, and molded block methods of the prior art.
SUMMARY
In some examples, a wall block comprises a first end portion comprising a first face and first and second opposing side surfaces; a second end portion comprising a second face and third and fourth opposing side surfaces; and an intermediate portion extending between and interconnecting the first and second end portions; wherein the first and second side surfaces taper toward each other extending in a direction from the first face toward the second face; wherein the third and fourth side surfaces taper toward each other extending in a direction from the second face toward the first face.
In some examples, the intermediate portion comprises two parallel legs separated by a core extending the height of the block.
In some examples, the first end portion has a first depth and the second end portion has a second depth, wherein the first depth equals the second depth.
In some examples, the first end portion comprises at least one first core configured to receive a block-connecting element and the second end portion comprises at least one second core configured to receive a block-connecting element.
In some examples, the first and second cores are spaced equidistant from a line parallel to the first and second faces and bisecting the block.
In some examples, the first face has a first length extending from the first side surface to the second side surface, and the second face has a second length extending from the third side surface to the fourth side surface, wherein the first length is greater than the second length.
In some examples, the intermediate portion comprises opposing and parallel fifth and sixth outer side surfaces, wherein the fifth and sixth side surfaces are perpendicular to the first and second faces.
In some examples, a first imaginary line coincident with the first side surface intersects a first end of the second face and a second imaginary line coincident with the second side surface intersects a second end of the second face.
In some examples, the block has a first void bounded by the first imaginary line, the third side surface, and the intermediate portion and a second void bounded by the second imaginary line, the fourth side surface, and the intermediate portion.
In some examples, the first face, the second face, the first side surface, the second side surface, the first imaginary line, and the second imaginary line define an isosceles trapezoid.
In some examples, a wall comprises a front surface and a rear surface, and further comprises at least a first lower course and a second upper course overlying the first course, wherein each course comprises a plurality of blocks, including at least a first subset of first blocks; wherein each first block comprises: a first end portion comprising a first face and first and second opposing side surfaces; a second end portion comprising a second face and third and fourth opposing side surfaces; and an intermediate portion extending between and interconnecting the first and second end portions; wherein the first and second side surfaces taper toward each other extending in a direction from the first face toward the second face; wherein the third and fourth side surfaces taper toward each other extending in a direction from the second face toward the first face.
In some examples, a first block of the first course is interconnected with a first block of the second course via a block-connecting element.
In some examples, the first block of the first course is set back relative to the first block of the second course to form a positive batter.
In some examples, the first block of the first course is set forward relative to the first block of the second course to form a negative batter.
In some examples, the first faces of one or more first blocks are exposed in the front surface of the wall and the second faces of one or more first blocks are exposed in the front surface of the wall.
In some examples, the plurality of blocks of each course includes a second subset of second blocks, wherein the second blocks have first and second faces, wherein the first faces of the second blocks are longer than the first faces of the first blocks.
In some examples, the first blocks and the second blocks have the same shape.
In some examples, a method of constructing a wall from blocks comprises forming a first course of blocks arranged side-by-side along the first course; and forming a second course of blocks on top of the first course, the second course comprising blocks arranged side-by-side along the second course; wherein the blocks of the first and second courses include at least a first subset of first blocks, wherein each first block comprises: a first end portion comprising a first face and first and second opposing side surfaces; a second end portion comprising a second face and third and fourth opposing side surfaces; and an intermediate portion extending between and interconnecting the first and second end portions; wherein the first and second side surfaces taper toward each other extending in a direction from the first face toward the second face; wherein the third and fourth side surfaces taper toward each other extending in a direction from the second face toward the first face.
In some examples, the method further comprises interconnecting a first block of the first course and a first block of the second course with a separate block-connecting element.
In some examples, the first faces of one or more first blocks are exposed in a front surface of the wall and the second faces of one or more first blocks are exposed in the front surface of the wall.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a wall block, according to one example.
FIG. 2 is another perspective of the wall block of FIG. 1.
FIG. 3 is a top plan view of the wall block of FIG. 1.
FIG. 4 is a bottom plan view of the wall block of FIG. 1.
FIG. 5 is a side view of the wall block of FIG. 1.
FIG. 6 is an elevation view of the first face of the wall block of FIG. 1.
FIG. 7 is an elevation view of the second face of the wall block of FIG. 1.
FIG. 8 is a perspective view of a wall block, according to another example.
FIG. 9 is a top plan view of the wall block of FIG. 8.
FIG. 10 is a bottom plan view of the wall block of FIG. 8.
FIG. 11 is an elevation view of the first face of the wall block of FIG. 8.
FIG. 12 is an elevation view of the second face of the wall block of FIG. 8.
FIG. 13 is a perspective view of a block-connecting element, according to one example.
FIG. 14 is a side view of the block-connecting element of FIG. 13.
FIG. 15 is a top view of the block-connecting element of FIG. 13.
FIG. 16 is a bottom view of the block-connecting element of FIG. 13.
FIG. 17 is a rear-side view of the block-connecting element of FIG. 13.
FIG. 18 is a front-side view of the block-connecting element of FIG. 13.
FIGS. 19 and 20 show examples of walls constructed from multiple blocks of the type shown in FIG. 1.
FIGS. 21 and 22 show examples of walls constructed from different size blocks of the type shown in FIG. 1.
FIGS. 23 and 24 show an example of constructing a wall having a 90-degree corner using blocks of the types shown in FIGS. 1 and 8.
FIGS. 25 and 26 show another example of constructing a wall having a 90-degree corner using blocks of the types shown in FIGS. 1 and 8.
FIGS. 27 and 28 show an example of a wall constructed from multiple blocks of the type shown in FIG. 1 and having a positive batter.
FIGS. 29 and 30 show an example of a wall constructed from multiple blocks of the type shown in FIG. 1 and having a neutral batter.
FIGS. 31 and 32 show an example of a wall constructed from multiple blocks of the type shown in FIG. 1 and having a negative batter.
FIGS. 33 and 34 show an example of a wall constructed from multiple blocks of the type shown in FIG. 1 and having a positive batter, in which the blocks are oriented in different directions.
FIGS. 35 and 36 show an example of a wall constructed from multiple blocks of the type shown in FIG. 1 and having a neutral batter, in which the blocks are oriented in different directions.
FIGS. 37 and 38 show an example of a wall constructed from multiple blocks of the type shown in FIG. 1 and having a negative batter, in which the blocks are oriented in different directions.
FIG. 39 shows an example of a block assembly comprising three blocks of the type shown in FIG. 1 that have different sizes.
DETAILED DESCRIPTION
General Considerations
For purposes of this description, certain aspects, advantages, and novel features of examples of this disclosure are described herein. The present disclosure is directed toward all novel and nonobvious features and aspects of the various disclosed examples, alone and in various combinations and sub-combinations with one another. The methods, apparatus, and systems are not limited to any specific aspect or feature or combination thereof, nor do the disclosed examples require that any one or more specific advantages be present or problems be solved.
Although the operations of some of the disclosed examples are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed methods can be used in conjunction with other methods. Additionally, the description sometimes uses terms like “provide” or “achieve” to describe the disclosed methods. These terms are high-level abstractions of the actual operations that are performed. The actual operations that correspond to these terms may vary depending on the particular implementation and are readily discernible by one of ordinary skill in the art.
As used in this application and in the claims, the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Further, the term “coupled” generally means physically, mechanically, chemically, magnetically, and/or electrically coupled or linked and does not exclude the presence of intermediate elements between the coupled or associated items absent specific contrary language.
Overview of the Disclosed Technology
In the following description, “upper” and “lower” refer to the placement of a block in a retaining wall. The lower, or bottom, surface of a block is placed such that it faces the ground. In a retaining wall, one row of blocks is laid down, forming a lowermost course or tier. An upper course or tier is formed on top of this lower course by positioning the lower surface of one block on the upper surface of another block. Additional courses may be added until a desired height of the wall is achieved. Typically, earth is retained behind a retaining wall so that only a front surface of the wall is exposed. A free-standing wall (i.e., one which does not serve to retain earth) having two exposed surfaces may be referred to as a “fence.” Any of the walls disclosed herein can be retaining walls or free-standing walls. Moreover, the blocks disclosed herein also can be used to construct columns.
According to one aspect, a block for constructing a wall, column, or other structure is configured to be reversible, that is, each face of the block can be used as the exposed face in a surface of a wall. Typically, one face of the block is larger than the other face of the block, and each face can be used as the exposed face in the front surface of the wall. In some cases, the first face of the block can be the same size as the second, opposed face of the block. According to another aspect, a plug and slot connection system for interconnecting blocks of adjacent courses permits alignment of blocks directly over one another, set forward, or set backward relative to one another so that either vertical or non-vertical walls may be constructed.
FIGS. 1-7 show a block 10 for constructing walls, columns, or other structures, according to one example. The block 10 can be made of concrete, using any known manufacturing techniques, such as dry-casting the block using a block-forming machine or wet-casting the block using a mold. The block 10 comprises a first end portion 12, a second end portion 14, and an intermediate or middle portion 16 extending between and interconnecting the end portions 12, 14. The first end portion 12 defines a first face 18 of the block and the second end portion 14 defines a second face 20 of the block.
The first end portion 12 comprises two opposing, angled side surfaces 22 that taper toward each other from the first face 18 toward the second face 20. The second end portion 14 comprises two opposing, angled side surfaces 24 that taper toward each other from the second face 20 toward the first face 18. Notably, providing the first and end portions 12, 14 with opposing tapers helps reinforce the faces 18, 20 and protects against breakage during handling and installation while also allowing for weight reduction of the block by reducing the amount of concrete required along the opposing sides of the block between the faces.
The intermediate portion 16 can include a center core 26 extending the height of the block and two parallel legs 28 extending from the first end portion 12 to the second end portion 14. In some examples, each leg 28 is centered at a “quarter point” of the block, meaning that each leg 28 is centered on an imaginary line that is perpendicular to the first face 18 and spaced one quarter of the overall length L1 of the first face from the closest end of the front face (where it intersects the side surface 22). The intermediate portion 16 has two outer side surfaces 60, which can be parallel to each other and perpendicular to the first and second faces 18, 20, respectively. In the illustrated example, each leg 28 defines one of the side surfaces 60.
As shown in FIG. 4, on each side of the block 10, an imaginary line 30 extends from the end of the first face 18 (where it intersects the adjacent side surface 22) to the end of the second face 20 (where it intersects the adjacent side surface 24). The dashed portion of each line 30 extends from the second face 20 to the closest edge of a side surface 22; however, it should be understood that each line 30 is coincident to and extends along a respective side surface 22 and therefore extends all the way from a first location at the intersection of the first face 18 and the respective side surface 22 to a second location at the intersection of the second face 20 and a respective side surface 24.
The first face 18, the second face 20, and the imaginary lines 30 define a trapezoidal footprint for the block as viewed from the top or bottom of the block. In some examples, the first face 18, the second face 20, and the imaginary lines 30 define an isosceles trapezoid. The shape of the block having such a trapezoidal footprint allows the block to be “reversible” such that the first face 18 or the second face 20 can serve as the exposed face on one side of a wall without any gaps between adjacent blocks when placed side-by-side in a course of the wall. The space between each line 30 and the adjacent side surface 24 and the outer surface 60 of the leg 28 defines relatively large voids, notches or cut-outs 50 along the sides of the block, which significantly reduces the overall weight of the block compared to a trapezoidal block that has straight side surfaces without any voids, notches or cut-outs.
Because the block 10 is reversible, the surface texture of the first face 18 desirably is the same as that for the second face 20, although this is not required. Since the first face 18 is larger than the second face 20, a wall constructed from such blocks takes on a more random, natural appearance, than a wall in which the exposed faces of all blocks are equal in size. Although not shown, both the first face 18 and the second face 20 can be provided with a roughened, split look to contribute to the natural appearance of the wall. The block also may be “tumbled” to round the edges and corners of the block, as generally known in the art. Alternatively, the block 10 may be molded so that either of faces 18, 20 has any desired pattern or a smooth surface.
The first end portion 12, the second end portion 14, and the intermediate portion 16 collectively define an upper surface 32 of the block and a parallel lower surface 34 of the block. As best shown in FIG. 3, the first end portion 12 includes at least one core extending the height of the block from the upper surface 32 to the lower surface 34. In the illustrated example, the first end portion 12 includes two cores 36 separated by a web 38, which can extend the height of the block. The upper surface 32 can include a recess 40 (such as a rectangular recess as shown) surrounding the web 38 and the cores 36. Similarly, the second end portion 14 includes a core 42 extending the height of the block from the upper surface 32 to the lower surface 34 and a recess 44 in the upper surface 32 surrounding the core 42. The cores 36, 42 are sized and shaped to receive a block-connecting element used for interconnecting vertically adjacent blocks in a wall, as further described below. In some examples, the cores 36 in the first end portion 12 and the core 42 in the second end portion 14 are spaced equidistant from an imaginary line 46 bisecting the block 10, which allows a block-connecting element to engage a core 36 of one block and a core 42 of a vertically adjacent block when a wall is constructed from blocks oriented in different directions, as further described below.
The first face 18 has a length L1 and the second face 20 has a length L2, wherein L1 is greater than L2. The block 10 has an overall depth D1 (measured from the first face 18 to the second face 20). The first end portion 12 has a depth D2 and the second end portion 14 has a depth D3. In some examples, D2 is equal to D3, and the legs 28 are centered on the imaginary line 46 bisecting the block located equidistant from the first face 18 and the second face 20.
In some examples, a block assembly for constructing a wall can include a set of two or more different size blocks 10 all having the same shape, the same overall height H (from the upper surface 32 to the lower surface 34), and the same depth D1, but the first faces 18 and/or the second faces 20 have different lengths.
FIG. 39 shows one example of a block assembly comprising a first block 10S, a second block 10M, and a third block 10L. The first block 10S can be referred to as a small block; the second block 10M can be referred to as a medium block; and the third block 10L can be referred to as a large block. The lengths of the first and second faces 18, 20 of the first block 10S are L1 and L2, respectively; the lengths of the first and second faces 18, 20 of the second block 10M are L3 and L4, respectively; and the lengths of the first and second faces 18, 20 of the third block 10L are L5 and L6, respectively. In some examples, L5 is greater than L3 and L3 is greater than L1. In some examples, L6 is greater than L4 and L4 is greater than L2. In some examples, the lengths of the second faces 20 of two or more of the blocks can be the same. For example, length L4 and length L2 can be the same. In some examples, each length L1, L2, L3, L4, L5, and L6 is a multiple of the same number, n, greater than one (e.g., two, four, six, etc.), which facilitates use of each block in both orientations (i.e., either face 18, 20) in the exposed surface of the wall.
In some examples, each block 10S, 10M, and 10L can have the same shape and configuration as described above for block 10, expect for the differences in the lengths of the first and second faces 18, 20. In some examples, as shown in FIG. 39, the block 10L optionally can have a web portion 52 extending from the first end portion 12 to the second end portion 14 within the center core 26 to reinforce the block at that location. The block 10L also optionally can have a web portion 54 in the second end portion 14 so as to define two cores 42 in the second end portion 14 to reinforce the block at that location.
Table 1 below shows the dimensions of one specific example of the block assembly of FIG. 39. All three blocks 10S, 10M, 10L have a depth D1 of about 10⅛ inches. The overall height H of each block 10S, 10M, 10L can be 6 inches in some examples or 8 inches in some examples. However, these dimensions and other dimensions disclosed herein can be adjusted as needed for a particular application.
|
Length of first
Length of second
|
Block
face 18
face 20
|
|
Block 10S
L1 is 16 inches
L2 is 12 inches
|
Block 10M
L3 is 18 inches
L4 is 12 inches
|
Block 10L
L5 is 24 inches
L6 is 20 inches
|
|
FIGS. 8-12 show a block 100 that can be used a corner block for forming 90-degree corners of a wall. Thus, the block 100 can be referred to as a “corner block”. The block 100 comprises a first face 102, a second face 104 that is parallel to the first face 102, a first side surface 106, a second side surface 108, an upper surface 110, and a lower surface 112 that is parallel to the upper surface 110. The first side surface 106 is oriented at an acute angle relative to the first face 102 and an obtuse angle relative to the second face 104 and therefore is non-perpendicular to the first and second faces. The second side surface 108 is perpendicular to the first and second faces 102, 104.
The block 100 further includes at least one core 112 adjacent the first face 102 and at least one core 114 adjacent the second face 104. In the illustrated example, there are two cores 112 separated by a web 116 and two cores 114 separated by a web 118. The upper surface 110 can be formed with a recess 120 surrounding the cores 112 and the web 116 and a recess 122 surrounding the cores 114 and the web 118. The block 100 can further comprises at least one center core 124, such as two center cores 124 separated by a web portion 126. The cores 112, 114, 124 can extend the height of the block 100 from the lower surface 112 to the upper surface 110.
The block 100 can be used in a block assembly comprising blocks 10 all of the same size, or an assembly comprising different size blocks 10 (such as the block assembly of FIG. 39).
As noted above, each of blocks 10, 100 is formed with cores that are configured to receive one or more block-connecting elements, such as block-connecting elements 500 (FIGS. 13-18) for interconnecting vertically adjacent blocks in a wall. The block-connecting element 500 can be referred to as a “three-way” block-connecting element (or “three-way” alignment plug) because it can be positioned in three different positions within a core of a block to permit vertical, set forward, or set back placement of blocks in a course relative to the blocks in an adjacent lower course, as further described below.
As shown in FIGS. 13-18, the block-connecting element 500 comprises a lower portion, or projection, 502, an upper portion, or projection, 504, and an intermediate flange portion 506 separating the upper and lower portions. The lower portion 502 can be formed with vertically extending, spaced-apart ribs 508 that extend outwardly from one or more sides of the lower portion (e.g., in the illustrated example, the ribs 508 are formed on three sides of the lower portion). The ribs 508 desirably taper in height extending in a direction from the flange portion 506 to the lower end of the lower portion 502. When inserted into a block, the ribs 508 can contact one or more inner surfaces of a core of the block to assist in frictionally retaining the block-connecting element within the block. Likewise, the upper portion 504 can be formed with vertically extending, spaced-apart ribs 510 that extend outwardly from one or more sides of the upper portion (e.g., in the illustrated example, the ribs 510 are formed on three sides of the upper portion). The ribs 510 desirably taper in height extending in a direction from the flange portion 506 to the upper end of the upper portion 504. When inserted into a block, the ribs 510 can contact one or more inner surfaces of a core of the block to assist in frictionally retaining the block-connecting element within the block.
The upper portion 504 is horizontally offset from the lower portion 502; thus, the upper portion 504 is located closer to a forward edge 512 of the flange portion 506 and the lower portion 502 is located closer to a rear edge 514 of the flange portion 506. In the illustrated example, the upper portion 504 is aligned with the forward edge 512 while the lower portion 502 is spaced slightly from the rear edge 514 a distance d.
The block-connecting element 500 can be made from any of various suitable materials, including, but not limited to any of various polymers, metals, and/or composites (e.g., carbon fiber reinforced polymer or a glass fiber reinforced polymer). The block-connecting element 500 is a separate component from the wall blocks it is used with, meaning that the block-connecting element is not an integrally molded component of wall block.
FIG. 19 shows an example of a wall constructed from multiple blocks 10 all of the same size with the first faces 18 oriented in the same direction such that the exposed surface of the wall is comprised of only the first faces 18 of the blocks. FIG. 20 shows an example of a wall constructed from multiple blocks 10 all of the same size with the first faces 18 and the second faces 20 of the blocks forming the exposed surface of the wall. As shown, in each course of the wall, adjacent blocks are oriented in a different direction; that is, for each block 10 oriented with the first face 18 in the surface of the wall, the next adjacent block in the same course is oriented with the second face 20 in the surface of the wall.
FIG. 21 shows an example of a wall constructed from multiple blocks 10, 10′ of different sizes (the same shape and size except for L1 and/or L2) with all of the blocks oriented in the same direction such that exposed surface of the wall is comprised of the first faces 18 of the blocks 10 and the first faces 18′ of the blocks 10′. Thus, the wall can include a first subset of blocks 10 and a second subset of blocks 10′. For example, blocks 10 can represent blocks 10S and blocks 10′ can represent blocks 10M (FIG. 39). In some examples, a third subset of blocks with different face sizes can be included with blocks 10, 10′. For example, blocks 10L (FIG. 39) can be included in the wall, along with blocks 10S and 10M. In some examples, the wall can include any combination of blocks 10S, 10M, and 10L in each course of the wall.
FIG. 22 shows an example of a wall constructed from multiple blocks 10, 10′ of different sizes with adjacent blocks in each course oriented in different directions. Thus, the exposed surface of the wall includes the first and second faces 18, 20 of the blocks 10 as well as the first and second faces 18′, 20′ of the blocks 10′. Thus, the wall can include a first subset of blocks 10 and a second subset of blocks 10′. For example, blocks 10 can represent blocks 10M and blocks 10′ can represent blocks 10L (FIG. 39). In some examples, a third subset of blocks with different face sizes can be included with blocks 10, 10′. For example, blocks 10S (FIG. 39) can be included in the wall, along with blocks 10M and 10L. In some examples, the wall can include any combination of blocks 10S, 10M, and 10L in each course of the wall.
FIGS. 23-24 show an example of a wall constructed from multiple blocks 10 and having a 90-degree corner formed using blocks 100. The wall includes a first course 200a (FIG. 23), and second course 200b (FIG. 24) stacked on top of the first course. The first course 200a includes two corner blocks 100 oriented 90-degrees relative to each other at the corner. The second course 200b can include a block 10″ abutting a corner block 100 at the corner. The block 10″ is a block 10 that is modified to have a 90-degree side by removing the tapered sections of the end portions 12, 14 on one side of the block.
FIGS. 23 and 24 also illustrate how adjacent blocks 10 in a course abut each other when adjacent blocks have different orientations. As shown, on each side of the wall, one end of a face 20 of one block 10 can abut an adjacent end of a face 18 of an adjacent block 10 such that there are no gaps between the faces 18, 20 of adjacent blocks.
FIGS. 25-26 show another example of a wall constructed from multiple blocks 10 and having a 90-degree corner formed using blocks 100. The wall includes a first course 200a, and second course 200b stacked on top of the first course. The second course 200b includes a corner block 100 abutting a modified block 10″ at the corner. The first course 200a includes a 90-degree corner formed by positioning two corner blocks 100 in a perpendicular manner relative to each other.
FIGS. 27-28 show an example of a wall constructed from multiple blocks 10 of the same size, in which the blocks are oriented in the same direction and stacked on top of each other to form a wall with a positive batter. The wall has a front surface 600 and a rear surface 602. To interconnect blocks in vertically adjacent courses with a block-connecting element 500, the lower portion 502 of the block-connecting element is inserted into a core 36 of a lower block 10a with the upper portion 504 of the block-connecting element in a rearward position (oriented toward the rear 602 of the wall). The flange 506 sits within the recess 40 of the lower block 10a. The upper portion 504 extends into a core 36 of an upper block 10b. The upper portion 504 of the block-connecting element is not vertically aligned with the core 36 of the lower block 10a. This allows the upper block 10b to be set back with respect to the lower block 10b to form a wall having a positive batter.
FIGS. 29-30 show an example of a wall constructed from multiple blocks 10 of the same size, in which the blocks are oriented in the same direction and stacked on top of each other to form a wall with a neutral batter. The wall has a front surface 600 and a rear surface 602. In this case, each block connecting element 500 is in a neutral position in which the upper portion 504 of the block-connecting element is aligned with the core from which it extends. For example, the lower portion 502 is inserted into a core 36 of a lower block 10a such that the upper portion 504 is aligned with the core 36 of the lower block 10b. An upper block 10b is placed over the lower block 10a such that the upper portion 504 of the block-connecting element 500 extends into a core 36 of the upper block 10b. Because the upper portion 504 is aligned with the cores of the lower block 10a and the upper block 10b, the blocks 10a, 10b are vertically aligned and form a wall with a neutral batter.
FIGS. 31-32 show an example of a wall constructed from multiple blocks 10 of the same size, in which the blocks are oriented in the same direction and stacked on top of each other to form a wall with a negative batter. The wall has a front surface 600 and a rear surface 602. In this case, each block connecting element 500 is in a forward position in which the upper portion 504 of the block-connecting element is not aligned with the core from which it extends and is offset toward the front surface 600 of the wall. For example, the lower portion 502 is inserted into a core 36 of a lower block 10a such that the upper portion 504 is not aligned with the core 36 of the lower block 10a. An upper block 10b is placed over the lower block 10a such that the upper portion 504 of the block-connecting element 500 extends into a core 36 of the upper block 10b. Because the upper portion 504 is offset toward the front of the wall, the upper block 10b is set forward with respect to the lower block 10a to form a wall with a negative batter.
FIGS. 33-34 show an example of a wall constructed from multiple blocks 10 of the same size, in which the blocks are oriented in different directions and stacked on top of each other to form a wall with a positive batter. The wall has a front surface 600 and a rear surface 602. In this example, the block connecting elements 500 are oriented in the rearward position (similar to FIGS. 27-28). The wall is constructed similar to the wall of FIGS. 27-28, with the exception that since the blocks are oriented in different directions, both cores 36, 42 are utilized for interconnecting two vertically adjacent blocks with one block-connecting element. For example, the lower portion 502 of a block-connecting element 500 can extend into a core 36 of a lower block 10a and the upper portion 504 of the same block-connecting element extends into the core 42 of an upper block 10b. Alternatively, the lower portion 502 of a block-connecting element 500 can extend into a core 42 of a lower block 10a and the upper portion 504 of the same block-connecting element extends into the core 36 of an upper block 10b.
FIGS. 35-36 show an example of a wall constructed from multiple blocks 10 of the same size, in which the blocks are oriented in different directions and stacked on top of each other to form a wall with a neutral batter. The wall has a front surface 600 and a rear surface 602. In this example, the block connecting elements 500 are oriented in the neutral position (similar to FIGS. 29-30). The wall is constructed similar to the wall of FIGS. 29-30, with the exception that since the blocks are oriented in different directions, both cores 36, 42 are utilized for interconnecting two vertically adjacent blocks with one block-connecting element. For example, the lower portion 502 of a block-connecting element 500 can extend into a core 36 of a lower block 10a and the upper portion 504 of the same block-connecting element extends into the core 42 of an upper block 10b. Alternatively, the lower portion 502 of a block-connecting element 500 can extend into a core 42 of a lower block 10a and the upper portion 504 of the same block-connecting element extends into the core 36 of an upper block 10b.
FIGS. 37-38 show an example of a wall constructed from multiple blocks 10 of the same size, in which the blocks are oriented in different directions and stacked on top of each other to form a wall with a negative batter. The wall has a front surface 600 and a rear surface 602. In this example, the block connecting elements 500 are oriented in the forward position (similar to FIGS. 31-32). The wall is constructed similar to the wall of FIGS. 31-32, with the exception that since the blocks are oriented in different directions, both cores 36, 42 are utilized for interconnecting two vertically adjacent blocks with one block-connecting element. For example, the lower portion 502 of a block-connecting element 500 can extend into a core 36 of a lower block 10a and the upper portion 504 of the same block-connecting element extends into the core 42 of an upper block 10b. Alternatively, the lower portion 502 of a block-connecting element 500 can extend into a core 42 of a lower block 10a and the upper portion 504 of the same block-connecting element extends into the core 36 of an upper block 10b.
FIGS. 27-38 show examples of walls constructed from multiple blocks of the same size. However, it should be noted that any of these walls can be constructed from blocks of different sizes (e.g., blocks having the same shape and dimensions except for different lengths L1 and/or L2, such as any combination of blocks 10S, 10M, and 10L of FIG. 39 and/or Table 1).
Further disclosure about using block-connecting elements for constructing walls is disclosed in U.S. Pat. No. 8,667,759, which is incorporated herein by reference.
In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims.
Patent Application
20250116109
