RETAINING WALL BLOCK AND METHOD OF MANUFACTURE
An interlocking segmental retaining wall. The wall includes a plurality of blocks stacked upon each other. Each block includes a recess formed thereacross. The recess is formed with tapered walls to facilitate molding.
The present application claims priority to, and incorporates by reference the entirety of U.S. Provisional Application Ser. No. 61/021956 filed Jan. 18, 2008.
BACKGROUND OF THE INVENTION1. Field of the Invention
The present invention relates to retaining walls, and more particularly, but not by way of limitation, to retaining wall blocks and methods of manufacture. The retaining wall blocks are of selectively reduced weight and may be used with optional, select stabilizing elements and methods therewith and fabricated from concrete or other materials.
2. History of Related Art
Retaining walls of various designs have been used in general construction, and particularly in landscaping for many years. The design of, the weight in, and the materials used for, such retaining walls have varied over time. Retaining walls are typically used to support or retain soil or the like in place, but also may be used to enhance the appearance of a surrounding area. Such walls typically stand on a ground region and retain there behind an earthen section or other fill material, which earthen section would otherwise form a natural slope in place of the retaining wall. Such retaining walls are typically vertical or at a slight angle. A generally vertical retaining wall may begin to deform as a mass of the earth retained behind it presses against it. A wall must resist this tendency. In addition, designers of retaining walls are constantly striving to construct more economical and aesthetically pleasing retaining walls having greater strength and less weight.
One of the most popular, and aesthetically pleasing forms of retaining wall construction involves the use of manually positionable individual blocks. The blocks may be stacked on top of the other to form a pattern on an outside face of the retaining wall. It can be very time consuming and tedious aligning numerous blocks to form the proper pattern in the retaining wall. Heavier retaining wall blocks are typically harder to handle than lighter weight blocks. In addition, a retaining wall may have one or more curved portions. The very design of many retaining wall blocks to assist in maintaining stability may be counter to the formation of a curved wall portion. In addition, certain retaining wall anchors are very cumbersome and laborious to install. Wall anchors include one end which is placed in a void of a retaining wall block. The block is then filled with concrete or similar substance in order to secure the anchor attachment. The concrete must then dry or settle before the assembly of the retaining wall can continue. A block for retaining walls and a retaining wall system is needed which provides enhanced structural support for individual blocks in both curved and linear wall portions, and is simple to use as well as simple and inexpensive to manufacture.
Related art references discussing subject matter bearing some relations to matters discussed herein include U.S. Pat. No. 5,941,042 to Dueck (Dueck), U.S. Pat. No. Re. 37,278 to Forsberg (Forsberg), U.S. Pat. No. 5,704,183 to Woolford (Woolford), U.S. Pat. No. 4,964,761 to Rossi (Rossi), U.S. Pat. No. 5,214,898 to Beretta (Beretta), U.S. Pat. No. 5,294,216 to Sievert (Seivert), U.S. Pat. No. 5,711,130 to Shatley (Shatley), U.S. Pat. No. 5,484,236 to Gravier (Gravier), German Gebrauschsmuster DE 295 00 694 U1 to Ming Su (Ming Su), U.S. Pat. No. 5,865,006 to Dawson (Dawson), U.S. Pat. No. 380,560 to Forsberg, U.S. Design Pat. No. 384,168 to Stevenson, U.S. Design Pat. No. 397,451 to Stevenson, U.S. Pat. No. 5,540,525 to Miller (Miller), U.S. Pat. No. 5,800,097 to Martin (Martin), U.S. Pat. No. 5,487,623 to Anderson et al (Anderson), U.S. Pat. No. 5,881,511 to Keller, Jr. (Keller), U.S. Pat. No. 5,524,551 to Scheiwiller (Scheiwiller), U.S. Pat. No. 6,260,320 B1 to Di Lorenzo (Di Lorenzo), U.S. Pat. No. 5,226,275 to Trahan (Trahan), U.S. Pat. No. 4,824,293 to Brown (Brown), U.S. Pat. No. 5,522,682 to Eagan (Egan), and U.S. Pat. No. 6,176,059 B1 to Cantarano et al (Cantarano).
In broad terms, and not to be interpreted as comprehensive, the above patents may be said to disclose the following: Dueck discloses a retaining wall block with downward-extending cylindrical knobs. Forsberg discloses pins and pockets for interlocking overlapping blocks. Woolford discloses a masonry block which has a centrally-located and dogbone-shaped, or two centrally-located circular, protrusions aligned with an opposing inset (or insets) extending partially into the block. Rossi discloses dry-mounted construction elements for use in a retaining wall with a series of openings within each block. Beretta discloses retraining wall blocks with a cambered front, tapering side walls and an abutment for engagement with an adjacent lower block. Sievert discloses a solid composite masonry retaining wall block with a flange extending down from the block back surface past the height of the block. Shatley discloses a retaining wall building block with rearward and forward aligning elements extending downward, holes extend through the blocks and pins for interlocking them together. Graiver discloses retaining wall blocks with an upward lateral extending front lip and a laterally extending recess. Dawson discloses a retaining wall block with a flange extending downward from the block's rear surface. The Forsberg design patent discloses a three faceted broken front face retaining wall block with a rear edge protrusion from the bottom surface of the block. The 384,168 Stevenson design patent discloses a retaining wall block with 2 rear protrusions from the bottom surface of the block. The 397,451 Stevenson design patent discloses a portion of a retaining block wall using the retaining wall blocks of the U.S. Pat. No. 384,168 design patent. Miller discloses a groove in the side of a block. Martin discloses an array of projections on the top face of a block that fits into an array of apertures on a bottom fact of a higher block. Anderson discloses vertical rods inserted through holes of the blocks in order to form reinforced columns. Keller discloses block having a dovetail section for fitting together with adjacent blocks. The Scheiwiller discloses blocks having holes for attaching with other blocks by filling the holes with concrete. Di Lorenzo discloses wall flanges held together by rods or cables that are held in each adjacent brick. Trahan discloses a block with a lower lip that fits into the block below it. Brown discloses a wall using a tieback to connect to a lower member. Egan discloses a modular wall block with rearward abscesses for receiving grid connectors. Cantarano discloses a wall form panel with interlocking protrusions around the edges which make the panel reversibly symmetric.
SUMMARY OF THE INVENTIONThe present invention relates to retaining wall blocks of reduced weight and methods of manufacture. More particularly, one aspect of the present invention includes a retaining wall block and method of manufacture incorporating a recessed mounting surface for reducing weight and/or receiving a stabilizing element facilitating securement of the stabilizing element with an anchoring element, thereby providing additional support and sturdiness to the retaining wall block system. In one embodiment, the recessed mounting surface is contiguous to a hollow central section of the type conventional in certain retaining wall block manufacture.
A more complete understanding of the method and apparatus of the present invention may be obtained by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings wherein:
Various embodiments of the present invention will now be described more fully with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be constructed as limited to the embodiments set forth herein; rather, the embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
Applicant of the present patent application has discovered that the use of hollow, lighter weight retaining wall blocks with a specially formed surface recess is an advantage from both cost and handling standpoints. In certain instances, the retaining wall block must be positioned in a configuration necessitating special attention in the stabilization of the individual retaining wall blocks. The present retaining wall blocks have been particularly configured for both lighter weight, ease of manufacture and receipt of a stabilization bar.
Referring now to
The indentation 22 of
As referenced above, the weight of the retaining wall block is critical in both cost of materials as well as shipping and handling. Techniques to reduce weight and improve efficiency in manufacture are important. The angulated configuration of indentation 22 in the trapezoidal configuration referred to herein, provides an improvement in retaining wall blocks by improving the ease with which such indentations may be made by a molding machine. For example, in the situation where an indentation is generally only rectangular in shape, the amount of pressure necessary to impart such an indentation in a retaining wall block during molding is much greater than with the present design having the angulated walls 32 and 34. Because of this design aspect, the capacity of select molding machines may be met with larger block sizes. There is also flexibility in using machines with less capacity for creating an indentation consistent with the present invention as well as increasing the size of the indentation. The presentation of the optional hollow region 24 (shown in
It may thus be seen from
Referring now to
Referring now to
Referring now to the above referenced U.S. Pat. No. 6,464,432 B1 (the '432 patent) there is shown a retaining wall block with a central section which is hollow.
The blocks 1 are stacked one on top of another to form a retaining wall 3. However, as illustrated in
Referring now to
It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. While the method and apparatus shown or described has been characterized as being preferred it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the invention as defined in the following claims.
Claims
1. An interlocking retaining wall block, adapted for assembly into a retaining wall system including a plurality of stacked rows of at least a plurality of said blocks, said block comprising:
- left, right, front and rear body portions, said front and rear body portions of said blocks being connected by said left and right body portions, defining a first surface;
- a substantially planar second, opposite surface of said block;
- at least one indentation formed across said first surface, the indentation having at least two angulated side walls facilitating fabrication thereof; and
- at lease one aligning element extending from said first surface of said block.
2. The interlocking retaining wall block of claim 1, wherein the at least one aligning element extends in generally parallel spaced relationship from the at least one indentation formed across said first surface.
3. The interlocking retaining wall block of claim 1, further comprising a central void formed through said retaining wall block to reduce weight thereof.
4. The interlocking retaining wall block of claim 3, wherein the central void extending through said block is defined by wall portions in generally parallel spaced relationship with the left and right body portions of said block.
5. The interlocking retaining wall block of claim 1, wherein the at least one indentation comprises first and second wall sections in generally parallel spaced relationship contiguous a bottom surface comprised of angulated walls extending therefrom and extending into said block.
6. The interlocking retaining wall block of claim 5, wherein said first and second wall portions are in generally parallel spaced relationship with said the at least one aligning element extending from said first surface of said block.
7. The interlocking retaining wall block of claim 1, further comprising at least two angulated corner regions between said front and said left and right body portions of said block.
8. The interlocking retaining wall block of claim 1, further comprising said at least one aligning element extending substantially across said first surface along said rear body portion to serve as an alignment element during installation of said block one atop another.
9. The interlocking retaining wall block of claim 1, wherein said block is formed of concrete.
10. The interlocking retaining wall block of claim 1, wherein said block is formed of injection molded plastic.
11. A method of manufacturing an interlocking retaining wall block, adapted for assembly into a retaining wall system including a plurality of stacked rows of at least a plurality of said blocks, said method comprising:
- forming male and female molds adapted to form left, right, front and rear body portions of a block, said front and rear body portions of said blocks being connected by said left and right body portions, defining a first surface;
- molding said block with a substantially planar second, opposite surface from said first surface;
- molding at least one indentation formed across said first surface, the indentation having at least two angulated side walls facilitating fabrication thereof; and
- molding at least one aligning element extending from said first surface of said block.
12. The method of claim 11, wherein the at least one aligning element extends in generally parallel spaced relationship from the at least one indentation formed across set first surface.
13. The method of claim 11, further comprising forming a central void through said retaining wall block to reduce the weight thereof.
14. The method of claim 13, wherein the central void extends through said block, defined by certain wall portions in generally parallel spaced relationship with the left and right body portions of said block.
15. The method of claim 11, wherein the at least one indentation is formed with first and second wall sections in generally parallel spaced relationship contiguous a bottom surface comprised of angulated walls extending therefrom and extending into said block.
16. The method of claim 15, wherein said first and second wall portions are formed in generally parallel spaced relationship with the at least one aligning element extending from said first surface of said block.
17. The method of claim 11, further comprising forming at least two angulated corner regions between said front and said left and right body portions of said block.
18. The method of claim 11, further comprsing forming said at least one aligning element in a position extending substantially across said first surface along said rear body portion to serve as an alignment element during installation of said block one atop another.
19. The method of claim 11, wherein said block is formed of concrete.
20. The method of claim 11, wherein said block is formed of injection molded plastic.
Type: Application
Filed: May 7, 2008
Publication Date: Jul 23, 2009
Inventor: Kenneth L. Shaw (Double Oak, TX)
Application Number: 12/116,702