Construction block

Abstract

A modular construction block is adapted for being assembled together with a number of other blocks in stacked courses to form a wall. The construction block includes first and second opposing block faces, a top and bottom, and opposing ends. The first block face has a first plurality of vertical score lines. The second block face has a second plurality of vertical score lines. The first and second plurality of vertical score lines resemble respective mortar joints, whereby the assembled wall resembles a brick structure.

Description

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

This invention relates generally to a modular construction block, and more specifically, to molded concrete blocks used in the construction of retaining walls, neighborhood entry walls, structural and decorative columns, commercial and residential landscaping, privacy fences, and the like. The invention has vertical score lines formed at predetermined locations with each opposing block face. When the blocks are arranged in stacked courses to form a wall or column, the score lines are intended to resemble mortar joints of a traditional and more expensive brick structure. The faux or imitation brick pattern may be in the form of a running bond, Flemish bond, English bond, common bond, stacked bond, herringbone, or other custom pattern.

As a result of its relatively low cost, ease of manufacture and handling, concrete masonry block has emerged as one of the most popular and widely accepted material for use in constructing retaining walls and block fences. The present invention takes advantage of these and other benefits of concrete block, while providing the look of a brick structure in any of a variety of common brick patterns. Achieving these same patterns using conventional brick can be labor intensive and costly. Moreover, the resulting brick structure is often less structurally sound that one constructed of concrete block.

SUMMARY OF THE INVENTION

Therefore, it is an object of the invention to provide a construction block with score lines adapted to resemble mortar joints of a traditional brick structure.

It is another object of the invention to provide a construction block which is readily and conveniently assembled with like blocks to form an imitation brick structure, such as a privacy fence or landscape wall.

It is another object of the invention to provide a construction block which has different patterns of score lines formed with each face-the first block face being exposed on one side of the structure in a first block course and the second block face being exposed on the same side of the structure in an adjacent block course.

It is another object of the invention to provide a modular construction block for being assembled with other blocks to form a wall, fence, column, or other structure, the blocks being formed with score lines resembling mortar joints such that the resulting wall resembles a running bond brick pattern.

It is another object of the invention to provide a modular construction block for being assembled with other blocks to form a wall, fence, column, or other structure, the blocks being formed with score lines resembling mortar joints such that the resulting wall resembles a Flemish bond brick pattern (with alternating headers and stretchers on each course).

It is another object of the invention to provide a modular construction block for being assembled with other blocks to form a wall, fence, column, or other structure, the blocks being formed with score lines resembling mortar joints such that the resulting wall resembles an English bond brick pattern (with alternating courses of headers and stretchers).

It is another object of the invention to provide a modular construction block for being assembled with other blocks to form a wall, fence, column, or other structure, the blocks being formed with score lines resembling mortar joints such that the resulting wall resembles brick laid in common bond with multiple course headers.

It is another object of the invention to provide a modular construction block for being assembled with other blocks to form a wall, fence, column, or other structure, the blocks being formed with score lines resembling mortar joints such that the resulting wall resembles a herringbone brick pattern (with each course resembling bricks laid at an angle).

It is another object of the invention to provide a modular construction block for being assembled with other blocks to form a wall, fence, column, or other structure, the blocks being formed with score lines resembling mortar joints such that the resulting wall resembles a stack bond brick pattern.

It is another object of the invention to provide a method for constructing a concrete block structure which resembles a more traditional brick structure.

These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a modular construction block adapted for being assembled together with a number of other blocks in stacked courses to form a wall. The construction block includes first and second opposing block faces, a top and bottom, and opposing ends. The first block face has a first plurality of vertical score lines. The second block face has a second plurality of vertical score lines. The first and second plurality of vertical score lines resemble respective mortar joints, whereby the assembled wall resembles a brick structure.

The term “wall” is defined broadly herein to mean any vertical surface of a structure constructed of an assembly of modular blocks arranged in stacked courses. The element “vertical score line” refers to any score or groove which extends across the face of the block from its top to its bottom at any angle.

According to another preferred embodiment, the construction block defines an intermediate through-void extending from its top to its bottom.

According to another preferred embodiment, the construction block defines a pin slot adapted for receiving an elongated shear pin.

According to another preferred embodiment, the construction block defines an end void formed with at least one of its opposing ends.

According to another preferred embodiment, the first block face includes at least two vertical score lines.

According to another preferred embodiment, the second block face includes at least three vertical score lines.

According to another preferred embodiment, at least one mounting protrusion is integrally-formed with at least one of the top and bottom of the construction block.

According to another preferred embodiment, the bottom defines a beveled perimeter edge.

According to another preferred embodiment, the first plurality of vertical score lines consists of two vertical score lines, and the second plurality of vertical score lines consists of three vertical score lines.

In another embodiment, the invention is a wall including an assembly of modular construction blocks arranged in stacked courses. Each of the construction blocks includes first and second opposing block faces, a top and bottom, and opposing ends. The first block face has a first plurality of vertical score lines. The second block face has a second plurality of vertical score lines. The first and second plurality of vertical score lines resemble respective mortar joints, whereby the assembled wall resembles a brick structure.

According to another preferred embodiment, a post-tensioning member extends through a void formed with the construction block.

According to another preferred embodiment, the post-tensioning member is a rigid vertical rod.

According to another preferred embodiment, an elongated vertical shear pin extends within a pin slot of the construction block.

According to another preferred embodiment, a cap block covers the top of the construction block.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1 is a perspective view of a modular construction block according to one preferred embodiment of the present invention, and showing a first face of the construction block;

FIG. 2 is a perspective view of the modular construction block showing its opposing second face;

FIG. 3 is a view of the first face of the construction block;

FIG. 4 is a view of the second face of the construction block;

FIG. 5 is an end view of the construction block;

FIG. 6 is a perspective view of a shear pin adapted for use in a construction wall comprising an assembly of modular construction blocks;

FIG. 7 is a fragmentary perspective view of a construction wall according to one preferred embodiment of the present invention;

FIG. 8 is an enlarged fragmentary perspective view of the construction wall;

FIG. 9 is a further enlarged fragmentary perspective view of the construction wall, and showing the wall caps applied to the top course of block;

FIG. 10 is a perspective view showing an underside of a construction block according to a second preferred embodiment of the invention; and

FIG. 11 is a perspective view of a construction wall comprising an assembly of the wall blocks shown in FIG. 10.

DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE

Referring now specifically to the drawings, a modular construction block according to the present invention is illustrated in FIG. 1, and shown generally at reference numeral 10. The block 10 has first and second block faces 11 and 12, a top 14 and bottom 15, and opposing ends 16 and 17. The block faces 11, 12 define vertical score lines 21, 22 and 23, 24, 25, respectively. As shown in FIGS. 1 and 3, the first face 11 has two spaced-apart intermediate score lines 21, 22 extending from the top 14 to the bottom 15 of the block 10. The opposite face 12 of the block 10 shown in FIGS. 2 and 4 has three spaced-apart score lines 23, 24, 25—two score lines 23, 25 along respective vertical edges of the face 11 and one intermediate score line 24. The bottom edges of the block 10 are preferably beveled, as best shown in FIG. 5. When the blocks 10 are assembled, as described below, the score lines 21-25 resemble mortar joints of a traditional brick structure.

The block 10 shown in FIGS. 1-5 defines intermediate voids 27, 28, and 29, end voids 31 and 32, and pin slots 33, 34, 35, and 36 each extending through the block from its top 14 to bottom 15. The pin slots 33-36 are designed to receive respective nylon shear pins 40, such as that shown separately in FIG. 6. Each shear pin 40 has an elongated center portion 41, enlarged stoppers 42, 43, and opposing tips 44, 45. As shown in FIGS. 7 and 8, the center portion 41 is designed to insert through one of the intermediate voids 27 and 29 while the tips 44, 45 are received within respective pin slots 33-36 of adjacent upper and lower course blocks 10. The enlarged stopper 42, 43 prevents the shear pin 40 from sliding vertically through the pin slot 33-36 in the lower course block 10. Preferably, a single pin 40 extending through one of the intermediate voids 27, 28, 29 of a middle course block 10 and into respective pin slots 33-36 of adjacent upper and lower course blocks 10 provides sufficient shear resistance for each of the upper, middle, and lower course blocks 10 in the stacked wall “W”.

Referring to FIGS. 7, 8, and 9, the first course of block 10 is laid directly on a concrete footer 48 or other suitable foundation. Spaced-apart, vertical post-tensioning rods 49 extend upwardly from the footer 48 and pass through respective intermediate voids 28 and end voids 31, 32 in alternating courses of block 10. The block courses are stacked in a “running bond” arrangement with the first and second block faces 11, 12 exposed in alternating courses on each side of the wall “W”. For example, in the first block course of FIG. 7, the first block face 11 comprising two intermediate vertical score lines 21, 22 is exposed on the side of the wall “W” shown. The second, opposing block face 12 comprising three vertical score lines 23, 24, and 25 is exposed on the opposite side of the wall (not shown). When constructing the second course, the block 10 is flipped 180-degrees such that the second block face 12 with three vertical score lines 23, 24, 25 is now exposed on the side of the wall “W” shown. The score lines 21-25 in the stacked courses resemble mortar joints in a running bond brick pattern. The third and remaining courses are constructed with the blocks 10 arranged in the same manner in alternating courses.

As shown in FIG. 8, at about every fourth course of block 10, an enlarged washer 51 and threaded nut 52 is applied to a complementary-threaded end portion of the post-tensioning rod 49 to further secure the stacked courses. This practice is generally known in the prior art and described in U.S. Pat. No. 4,726,567. The complete disclosure of this prior patent is incorporated herein by reference. The top course of block 10 is likewise secured with an enlarged washer 53 and threaded nut 54, as shown in FIG. 9. To finish the wall “W”, a course of molded concrete caps 55 is applied over the last course of block 10. Each cap 55 has more closely spaced vertical score lines 56. These lines 56 are intended to resemble mortar joints between respective brick headers.

An alternative embodiment of a wall block 60 according to the present invention is shown in FIGS. 10 and 11. The underside of the block 60 comprises mounting protrusions 61, 62, 63, and 64 formed adjacent respective end voids 65 and 66. The mounting protrusions 61-64 are designed to fit with respective intermediate voids 67, 68, and 69 formed with like blocks 60 of a lower course, as shown in FIG. 11. The mounting protrusions 61-64 cooperate to guide proper placement of blocks 60 in successive stacked courses, and to increase the overall stability of the resulting wall without the use of shear pins or other mechanical course connectors. With the exception of the omitted shear pins and pin slots, all other features of the block 60 are identical to that described above with reference to the block 10.

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

Claims

1. A modular construction block adapted for being assembled together with a number of other blocks in stacked courses to form a wall, said construction block comprising:

(a) first and second opposing block faces, a top and bottom, and opposing ends;

(b) said first block face comprising a first vertical score line;

(c) said second block face comprising a second vertical score line; and

(d) said first and second vertical score lines resembling respective mortar joints, whereby the assembled wall resembles a brick structure.

2. A modular construction block according to claim 1, and defining an intermediate through-void extending from said top to said bottom.

3. A modular construction block according to claim 1, and defining a pin slot adapted for receiving an elongated shear pin.

4. A modular construction block according to claim 1, and defining an end void formed with at least one of said opposing ends.

5. A modular construction block according to claim 1, wherein said first block face comprises two vertical score lines.

6. A modular construction block according to claim 5, wherein said second block face comprises three vertical score lines.

7. A modular construction block according to claim 1, and comprising at least one mounting protrusion integrally-formed with at least one of said top and bottom.

8. A modular construction block according to claim 1, wherein said bottom defines a beveled perimeter edge.

9. A modular construction block according to claim 1, wherein said first block face consists of two vertical score lines, and said second block face consists of three vertical score lines.

10. A wall comprising an assembly of modular construction blocks arranged in stacked courses, each of said construction blocks comprising:

(a) first and second opposing block faces, a top and bottom, and opposing ends;

(b) said first block face comprising a first vertical score line;

(c) said second block face comprising a second vertical score line; and

(d) said first and second vertical score lines resembling respective mortar joints, whereby said assembled wall resembles a brick structure.

11. A wall according to claim 10, wherein said construction block defines an intermediate through-void extending from its top to its bottom.

12. A wall according to claim 11, and comprising a post-tensioning member extending through the void formed with said construction block.

13. A wall according to claim 12, wherein said post-tensioning member comprises a rigid vertical rod.

14. A wall according to claim 10, wherein said construction block defines a pin slot.

15. A wall according to claim 14, and comprising an elongated vertical shear pin extending within the pin slot of said construction block.

16. A wall according to claim 10, and comprising a cap block covering the top of said construction block.

17. A wall according to claim 10, wherein said construction block defines opposing end voids.

18. A wall according to claim 10, wherein the first block face of said construction block comprises two vertical score lines.

19. A wall according to claim 18, wherein the second block face of said construction block comprises three vertical score lines.

20. A wall according to claim 10, wherein the first block face of said construction block consists of two vertical score lines, and the second block face consists of three vertical score lines.