Structural Unit and Positioning Member
A structural unit includes a body having a plurality of exterior surfaces, at least one receiving arrangement provided on at least a portion of the body, and at least one positioning member connected to the body. The at least one positioning member is separable from the body and configured for interaction with the at least one receiving arrangement.
This disclosure claims the benefit of U.S. Provisional Application No. 61/678,334, filed Aug. 1, 2012, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION1. Field of the Invention
The present disclosure relates to structural units, e.g., blocks, for walls, e.g., retaining walls, which are typically used to reinforce sloping embankments, and, more specifically, to a wall block having a positioning feature and arrangement for positioning and/or aligning the block relative to adjacent blocks.
2. Description of Related Art
Structural units, such as blocks, are formed from brick, stone, concrete, and other materials. The blocks may be stacked in rows to form walls, such as retaining walls and the like. Generally, the blocks are configured so that a row of blocks is connected to a row of blocks positioned immediately below with mechanical connections for the purpose of aligning and interlocking individual blocks of the upper row with the row below. These mechanical connections can be integrally molded into the blocks themselves, as in the case for lugs and lips projecting from the rear or front face of the block. The mechanical connections may also include a separate connector that is inserted in the top of a hole through the block and received by a corresponding receiving hole or slot in the block below. In the first case, the projection or lip is typically molded into the block and forms a connection to a block in the row below by resting against the top surface or side of the lower block. Lip systems typically are used to limit the setback or built-in slope of the wall to the degree established by the thickness of the projection.
In contrast, blocks connected by pins offer greater flexibility in the placement of the adjacent blocks. For example, the blocks can be configured with variations in the setback angle by varying the position of the receiving hole. The pins used in retaining wall blocks may be manufactured with various materials such as plastic, fiberglass, steel, and wood, and are typically supplied as an accessory necessary for proper construction of the wall. Pins can be expensive and add to the time and labor required to construct the retaining wall. Therefore, a need exists for a connector and connection arrangement for a retaining wall block, which offers the construction advantages of a pin.
SUMMARY OF THE INVENTIONGenerally, provided is a structural unit with a positioning member that addresses or overcomes some or all of the deficiencies and drawbacks associated with existing positioning arrangements utilized in connection with blocks for building a wall structure.
Accordingly, and in one preferred and non-limiting embodiment, provided is a structural unit with a positioning member/system for constructing a wall structure with a plurality of interconnected units. The structural units are configured to be placed in a side-by-side arrangement and stacked on top of each other to form a vertical structure, such as a wall. The units may be arranged in a recessed arrangement where upper rows of the wall structure are set back farther than lower rows. In one preferred and non-limiting embodiment, the wall structure is used for the purpose of preventing erosion of soil from a hillside or steep embankment. The wall may also include decorative features such as an ornamental or decorative front face or decorative curves for aesthetic purposes. In addition, in one preferred and non-limiting embodiment, the structural unit includes an integrated positioning member, such as in the form of a rod, a pin, an elongate member, and the like.
In one preferred and non-limiting embodiment, the structural unit includes a body having a plurality of exterior surfaces and at least one receiving arrangement. The structural unit further includes at least one positioning member connected to the body. The at least one positioning member is separable from the body and configured for interaction with the at least one receiving arrangement. In accordance with one preferred and non-limiting embodiment, the at least one receiving arrangement includes at least one receiving hole extending through at least a portion of the body and at least one aligning channel extending along an exterior surface of the body. The at least one positioning member is configured for insertion into the at least one receiving hole.
In another preferred and non-limiting embodiment, the at least one aligning channel is configured to interact with a portion of the at least one positioning member to position at least two structural units with respect to each other. The body and the at least one positioning member are formed from the same material.
In another preferred and non-limiting embodiment, the at least one receiving hole has a substantially cross-shaped cross section including a longitudinal slot and a transverse slot adapted to receive a substantially rectangular positioning member through one of the longitudinal slot or the transverse slot. Alternatively, the at least one receiving hole has a substantially circular cross-section and wherein the at least one positioning member is a cylinder configured for insertion into the substantially circular cross-section of the at least one receiving hole. In a further embodiment, the at least one receiving hole has a substantially mushroom-shaped cross-section including a semicircular portion and a slot portion extending from the diameter of the semicircular portion. In this embodiment, the at least one receiving hole is configured such that when the at least one positioning member is inserted parallel to the diameter of the semicircle, an adjacent block in a row above is positioned in a substantially vertical orientation, such that a front face of the block is substantially planar with a front face of the adjacent block in the row above, and wherein when the at least one positioning member is inserted perpendicular to the diameter of the semicircular portion, the adjacent block in the row above is in a set back orientation.
In another preferred and non-limiting embodiment, a plurality of structural units is positioned to form a row, wherein two or more rows of structural units are stacked on top of one another to form a wall. A first row is set back from a second row on which it is stacked, thereby forming a sloped wall. Alternatively, front faces of the structural units of a first row are substantially planar with front faces of the structural units of a second row below, thereby forming a substantially vertical retaining wall.
In accordance with another preferred and non-limiting embodiment, a retaining wall block includes a body having a plurality of exterior surfaces, at least one receiving arrangement provided on at least a portion of the body, and at least one positioning member connected to the body. The at least one positioning member is separable from the body and configured to interact with the at least one receiving arrangement and at least a portion of a second retaining wall block to position the retaining wall block relative to the second retaining wall block. The at least one receiving arrangement includes at least one receiving hole extending through at least a portion of the body and at least one aligning channel extending along an exterior surface of the body. The at least one positioning member is configured for insertion into the at least one receiving hole. The body and the at least one positioning member are formed from the same material.
In another preferred and non-limiting embodiment, the at least one receiving hole has a substantially cross-shaped cross section including a longitudinal slot and a transverse slot adapted to receive a substantially rectangular positioning member through one of the longitudinal slot or the transverse slot. Alternatively, the at least one receiving hole has a substantially circular cross-section and wherein the at least one positioning member is a cylinder configured for insertion into the substantially circular cross-section of the at least one receiving hole. In a further alternative and non-limiting embodiment, the at least one receiving hole has a substantially mushroom-shaped cross-section including a semicircular portion and a slot portion extending from the diameter of the semicircular portion. In this embodiment, the at least one receiving hole is configured such that when the at least one positioning member is inserted parallel to the diameter of the semicircle, an adjacent block in a row above is positioned in a substantially vertical orientation, such that a front face of the block is substantially planar with a front face of the adjacent block in the row above, and wherein when the at least one positioning member is inserted perpendicular to the diameter of the semicircular portion, the adjacent block in the row above is in a set back orientation.
In yet another preferred and non-limiting embodiment, a plurality of retaining wall blocks is positioned to form a row, and wherein two or more rows of retaining wall blocks are stacked on top of one another to form a wall. A first row is set back from a second row on which it is stacked, thereby forming a sloped wall. Alternatively, front faces of the retaining wall blocks of a first row are substantially planar with front faces of the retaining wall blocks of a second row below, thereby forming a substantially vertical retaining wall.
In a further preferred and non-limiting embodiment, a nested unit having two or more retaining wall blocks connected to one another by at least one face, wherein at least one of the two or more blocks includes a body having a plurality of exterior surfaces and at least one receiving arrangement provided on at least a portion of the body. The at least one of the blocks further includes at least one positioning member connected to the body. The at least one positioning member is separable from the body and configured to interact with the at least one receiving arrangement and at least a portion of an adjacent block to position the block relative to the adjacent block.
These and other features and characteristics of the present invention, as well as the methods of operation and functions of the related elements of structures and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
The following description is provided to enable those skilled in the art to make and use the described embodiments contemplated for carrying out the various embodiments described herein. Various modifications, equivalents, variations, and alternatives, however, will remain readily apparent to those skilled in the art. Any and all such modifications, variations, equivalents, and alternatives are intended to fall within the spirit and scope of the present invention. Further, for purposes of the description hereinafter, the terms “end”, “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”, “longitudinal” and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting. For the purpose of facilitating understanding of the invention, the accompanying drawings and description illustrate preferred embodiments thereof, from which the invention, various embodiments of its structures, construction and method of operation, and many advantages may be understood and appreciated.
As discussed hereinafter, the present invention is directed to a structural unit that is referred to as a “block”. It should be noted that this term—“block”—encompasses any type of structural unit that can be used in building a vertical structure, including, but not limited to, a wall, a retaining wall, a foundation, a building, and/or any type of structure. Various embodiments of the block (alone and/or in combination with other blocks) are shown and illustrated in
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The block 10 further includes a receiving hole 26 extending from the top surface 20 to the bottom surface 22 of the body 14. The receiving hole 26 may be molded directly into the block 10 or drilled into a pre-formed block. The receiving hole 26 is configured to receive a positioning rod 12 for aligning the block 10 relative to blocks 10 of the row below. As described in greater detail with respect to various preferred and non-limiting embodiments of the block 10 described hereinafter, the receiving hole 26 and corresponding positioning rod 12 can have many different shapes and sizes. For example, the receiving hole 26 could be circular or a rectangular slot and the positioning rod 12 could be rectangular. The receiving holes 26 may also be configured so that the positioning rod 12 can be inserted in varying orientations to adjust how the block 10 is positioned relative to the blocks 10 of the row below. More specifically, and in one preferred and non-limiting embodiment, the hole 26 and rod 12 are configured so that a block 10 cannot be placed directly on top of another block. In that case, the positioning rod 12 would fall through the hole 26 of both blocks and would not serve the function of positioning one block 10 relative to the other. Instead, in this preferred and non-limiting embodiment, the blocks 10 are staggered so that the positioning rod 12 of one block 10 passes through the receiving hole 26 and contacts at least a portion of the top surface 20 of the block below.
In one preferred and non-limiting embodiment, the positioning rod 12 is integrally and detachably molded to the block body 14. Having the positioning rod 12 molded into the blocks upon production eliminates the need to acquire separate pins during installation of the wall. Instead, the positioning structure/arrangement is integral with the block 10 and is delivered to the construction site at the same time as the blocks 10.
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According to one preferred and non-limiting embodiment of the invention, the positioning rod 12 is positioned in a recessed portion 32 of the rear face 18 of the body 14, for the purpose of protecting the positioning rod 12 during shipping. More specifically, the recessed portion 32 includes an exterior surface 34. The breakable extension 30 of the positioning rod 12 extends from the exterior surface 34 such that, in one preferred and non-limiting embodiment, exterior faces (e.g., the front, rear, top, bottom, and/or side exterior faces of the positioning rod 12) are substantially planar with or recessed with respect to one or more of the exterior faces of the block body 14, whether in a lateral or longitudinal dimension. In particular, the dimensions of at least a portion of the positioning rod 12 may be configured to prevent any part of the positioning rod 12 from extending farther than the planar faces of the block body 14. In this manner, the positioning rod 12 is protected because it does not extend past these exterior surfaces of the block body 14. In this way, it is less likely that the positioning rod 12 will be accidently impacted and/or detached from the block body 14 before the appropriate time.
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Furthermore, one or more splitting grooves 65 can be provided or molded on or with the nested unit 60, such as on any of the exterior faces of the nested unit 60. Such splitting grooves 65 aid in the splitting process and ensure that the nested unit 60 is accurately and appropriately separated. Also, in another preferred and non-limiting embodiment, the nested unit 60 can be split to create a rough surface on the resulting exterior face of the block 10 (normally the face at or near the splitting groove 65). Accordingly, the nested unit 60 provides an effective manner of obtaining a “split”-look architectural face (which occurs by this splitting process after the structural unit is cured and hardened). Of course, the blocks 10 or nested units 60 (or resulting wall) could be formed having one or more decorative or aesthetic faces, which may be applied or formed during the manufacturing process. For example, one or more of the exterior faces of the nested unit 60, the block 10, and/or the resulting wall could have a smooth face, a striated face, an embossed face, a textured face, and the like.
In a further preferred and non-limiting embodiment of the invention, a plurality of blocks 10 is assembled to form a retaining wall 410. Receiving holes 26 and positioning rods 12 of the individual blocks 10 allow for installation of blocks 10 in the desired orientation, as described above. More specifically, the retaining wall 410 may be built with a set back or substantially vertical orientation depending on how the rods 12 are inserted in the holes 26. With reference to
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While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of invention which is to be given the full breadth of the claims appended and any and all equivalents thereof. Further, although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.
Claims
1. A structural unit comprising:
- a body having a plurality of exterior surfaces;
- at least one receiving arrangement provided on at least a portion of the body; and
- at least one positioning member connected to the body,
- wherein the at least one positioning member is separable from the body and configured for interaction with the at least one receiving arrangement.
2. The structural arrangement of claim 1, wherein the at least one receiving arrangement comprises:
- at least one receiving hole extending through at least a portion of the body; and
- at least one aligning channel extending along an exterior surface of the body,
- wherein the at least one positioning member is configured for at least partial insertion into the at least one receiving hole.
3. The structural unit of claim 1, structural unit of claim 1, wherein the body and the at least one positioning member are formed from the same material.
4. The structural unit of claim 2, wherein the at least one aligning channel is configured to interact with a portion of the at least one positioning member to position at least two structural units with respect to each other.
5. The structural unit of claim 2, wherein the at least one receiving hole has a substantially cross-shaped cross section including a longitudinal slot and a transverse slot adapted to receive a substantially rectangular positioning member through one of the longitudinal slot or the transverse slot.
6. The structural unit of claim 2, wherein the at least one receiving hole has a substantially circular cross-section and wherein the at least one positioning member is a cylinder configured for insertion into the substantially circular cross-section of the at least one receiving hole.
7. The structural unit of claim 2, wherein the at least one receiving hole has a substantially mushroom-shaped cross-section including a semicircular portion and a slot portion extending from the diameter of the semicircular portion.
8. The structural unit of claim 6, wherein the at least one receiving hole is configured such that when the at least one positioning member is inserted parallel to the diameter of the semicircle, an adjacent block in a row above is positioned in a substantially vertical orientation, such that a front face of the block is substantially planar with a front face of the adjacent block in the row above, and wherein when the at least one positioning member is inserted perpendicular to the diameter of the semicircular portion, the adjacent block in the row above is in a set back orientation.
9. The structural unit of claim 1, wherein a plurality of structural units is positioned to form rows, and wherein rows of structural units are stacked on top of one another to form a wall.
10. The structural unit of claim 9, wherein a first row is set back from a second row on which it is stacked, thereby forming a sloped wall.
11. A retaining wall block comprising:
- a body having a plurality of exterior surfaces;
- at least one receiving arrangement provided on at least a portion of the body; and
- at least one positioning member connected to the body,
- wherein the at least one positioning member is separable from the body and configured to interact with the at least one receiving arrangement and at least a portion of a second retaining wall block to position the retaining wall block relative to the second retaining wall block.
12. The retaining wall block of claim 11, wherein the body and the at least one positioning member are formed from the same material.
13. The retaining wall block of claim 11, wherein the at least one receiving arrangement comprises:
- at least one receiving hole extending through at least a portion of the body; and
- at least one aligning channel extending along an exterior surface of the body,
- wherein the at least one positioning member is configured for at least partial insertion into the at least one receiving hole such that a lower portion of the at least one positioning member extends beyond a bottom surface of the body.
14. The retaining wall block of claim 13, wherein the at least one receiving hole has a substantially cross-shaped cross section including a longitudinal slot and a transverse slot adapted to receive a substantially rectangular positioning member through one of the longitudinal slot or the transverse slot.
15. The retaining wall block of claim 13, wherein the at least one receiving hole has a substantially circular cross-section and wherein the at least one positioning member is a cylinder configured for insertion into the substantially circular cross-section of the at least one receiving hole.
16. The retaining wall block of claim 13, wherein the at least one receiving hole has a substantially mushroom-shaped cross-section including a semicircular portion and a slot portion extending from the diameter of the semicircular portion.
17. The retaining wall block of claim 15, wherein the at least one receiving hole is configured such that when the at least one positioning member is inserted parallel to the diameter of the semicircle, an adjacent block in a row above is positioned in a substantially vertical orientation, such that a front face of the block is substantially planar with a front face of the adjacent block in the row above, and wherein when the at least one positioning member is inserted perpendicular to the diameter of the semicircular portion, the adjacent block in the row above is in a set back orientation.
18. The retaining wall block of claim 11, wherein a plurality of retaining wall blocks is positioned to form rows, and wherein rows of retaining wall blocks are stacked on top of one another to form a wall.
19. The retaining wall block of claim 17, wherein a first row is set back from a second row on which it is stacked, thereby forming a sloped wall.
20. A nested unit comprising two or more retaining wall blocks connected to one another by at least one face, wherein at least one of the two or more blocks comprises:
- a body having a plurality of exterior surfaces;
- at least one receiving arrangement provided on at least a portion of the body; and
- at least one positioning member connected to the body,
- wherein the at least one positioning member is separable from the body and configured to interact with at least one receiving arrangement and at least a portion of an adjacent block to position the block relative to the adjacent block.
Type: Application
Filed: Jul 31, 2013
Publication Date: Feb 6, 2014
Inventor: Robert L. Welling (Kittanning, PA)
Application Number: 13/955,490