Abstract:
One embodiment of modular wall blocks of the present disclosure can be implemented as follows. An interlocking retaining wall block, adapted for assembly into a retaining wall including a plurality of stacked rows of at least a plurality of said blocks. The block includes left, right, front and rear body portions, and left and right protruding body portions extending outwardly in left and right directions from said left and right body portions, respectively. The block further includes left and right aligning elements extending upwardly from an upper surface of said left and right protruding body portions, respectively, each of said aligning elements having an upper surface that is angled downwardly from rear to front, each of said aligning elements being operable to be received by a void of another one of said blocks.

Description:
TECHNICAL FIELD 
   The present disclosure is generally related to earth reinforcement and, more particularly, is related to modular retaining wall structures. 
   BACKGROUND 
   Modular earth retaining walls are commonly used for architectural and site development applications. A variety of retaining wall structures and reinforcement systems exist, such as those disclosed in U.S. Pat. Nos. 5,921,715; 6,322,291 B1; 6,338,597 B1; 6,416,257 B1; 6,652,196; 6,612,784 B2; 6,758,636 B2; 7,114,887 B1; and 7,390,146; all of which are entirely incorporated herein by reference. Generally, the modular earth retaining walls are constructed of modular blocks. However, it is not uncommon for these modular blocks to be damaged during storage and/or transportation. 
   SUMMARY 
   Embodiments of the present disclosure provide modular wall blocks which may be safely stacked for storage and/or transportation. Briefly described, one embodiment of the blocks, among others, can be implemented as follows. 
   An interlocking retaining wall block, adapted for assembly into a retaining wall including a plurality of stacked rows of at least a plurality of said blocks. The block includes left, right, front and rear body portions, said front and rear body portions of said block being connected by said left and right body portions, defining a void therebetween. The block further includes left and right protruding body portions, said left and right protruding body portions extending outwardly in left and right directions from said left and right body portions, respectively. The block further includes left and right aligning elements extending upwardly from an upper surface of said left and right protruding body portions, respectively, each of said aligning elements located forward of an exterior face of said rear body portion and rearward of an interior face of said front body portion on each of said left and right protruding body portions, each of said aligning elements having an upper surface that is angled downwardly from rear to front, each of said aligning elements being operable to be received by a void of another one of said blocks. The block further includes a substantially planar bottom surface of said block. 
   Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description and be within the scope of the present disclosure. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
       FIG. 1  is a diagram of one embodiment of a modular retaining wall in accordance with the present disclosure. 
       FIG. 2  is a diagram of a top view of one embodiment of a long horizontal block that is utilized in the modular retaining wall of  FIG. 1 . 
       FIG. 3  is a diagram of a front view of the long horizontal block of  FIG. 2 . 
       FIG. 4  is a diagram of a side view of the long horizontal block of  FIG. 2 . 
       FIG. 5  is a diagram of a top view of one embodiment of a long vertical block that is utilized in the modular retaining wall of  FIG. 1 . 
       FIG. 6  is a diagram of a side view of the long vertical block of  FIG. 5 . 
       FIG. 7  is a diagram of a top view of one embodiment of a half block that is utilized in the modular retaining wall of  FIG. 1 . 
       FIG. 8  is a diagram of a front view of the half block of  FIG. 7 . 
       FIG. 9  is a diagram of a side view of the long horizontal block of  FIG. 7 . 
       FIG. 10  is a diagram of a perspective view of one embodiment of an anchoring system constructed in accordance with the present disclosure. 
       FIG. 11  is a diagram of a side view of another embodiment of an anchoring system constructed in accordance with the present disclosure. 
       FIG. 12  is a diagram of perspective and side views of one embodiment of a long horizontal block that is utilized in the modular retaining wall of  FIG. 1 . 
       FIG. 13  is an illustration of the blocks of  FIG. 12  stacked for storage and/or transportation in accordance with the present disclosure. 
       FIG. 14  is a diagram of side views of embodiments of the block of  FIG. 12  illustrating different angling of the upper surface of the locking means in accordance with the present disclosure. 
       FIGS. 15-16  are diagrams of embodiments of a mold for forming wall blocks utilized in the wall structure described in  FIG. 1 . 
   

   DETAILED DESCRIPTION 
   Referring now in detail to the drawings, in which like numerals indicate corresponding parts throughout the several views,  FIG. 1  illustrates an embodiment of a modular or segmental retaining wall  10  in accordance with the present disclosure. As depicted in this figure, the retaining wall  10  comprises a plurality of wall blocks  30  that are stacked atop each other. The wall blocks  30 , when stacked together, form an exterior surface  40  of the wall  10  which faces outwardly away from an earth embankment, and an interior surface  50  of the wall  10  which faces inwardly toward the embankment. Typically, the blocks  30  are stacked in a staggered arrangement as shown in  FIG. 1  to provide greater stability to the modular retaining wall  10  and to provide ornamental decoration. 
   Modular or segmental retaining walls commonly comprise courses or tiers of modular units or blocks. The blocks are typically made of concrete. The blocks are typically dry-stacked (no mortar or grout is used), and often include one or more features adapted to properly locate adjacent blocks and/or courses with respect to one another, and to provide resistance to shear forces from course to course. The weight of the blocks is typically in the range of ten to one hundred fifty pounds per unit. Modular retaining walls commonly are used for architectural and site development applications. Such walls are subjected to high loads exerted by the soil behind the walls. These loads are affected by, among other things, the character of the soil, the presence of water, temperature and shrinkage effects, and seismic loads. To handle the loads, modular retaining wall systems often comprise one or more layers of soil reinforcement material extending from between the tiers of blocks back into the soil behind the blocks. 
   Generally speaking, the modular blocks  30 , in one embodiment, are comprised of, but not limited to, three blocks of different size and shape. In one configuration, each block is configured so as to mate with at least one other block when the blocks are stacked atop one another to form the modular retaining wall  10 . This mating restricts relative movement between vertically adjacent blocks in at least one horizontal direction and allows adjacent courses to be setback from one another. To provide for this mating, the blocks  30  can include locking means  60 , such as a raised notch or node, that secure the blocks together (e.g., by engaging against a bottom surface of an adjacent upper block) to further increase wall stability. 
   As demonstrated in  FIG. 1 , one type of modular block used in an embodiment of the disclosure is a “long horizontal block” or a standard block  32 .  FIG. 2  shows a top view of the long horizontal block  32 . As shown, one embodiment of the long horizontal block includes side channels  92  and an interior opening or cavity  72  that extends through the block vertically (top-to-bottom). The side channels  92  and interior opening  72  of the wall block  32  reduces the amount of concrete or other materials needed to fabricate the block  32  and reduce the weight of the block  32  to simplify wall construction. The opening  72  of the wall block  32  is sized so as to maximize the strength of the block  32  while still permitting space for connecting anchoring structures to the wall  10 , in some embodiments. 
   Further, locking means  62  are shown for securing another block positioned vertically atop the block  32 . In accordance with the present disclosure, a variety of faces of the block may be used to provide a different texture and design to the wall. As represented by the solid line  33   a  in the figure, the long horizontal block may feature a multiple sides or multi-split configuration. Alternatively, in some embodiments, as represented by the dashed lines  33   b ,  33   c , the face may feature offset splits, where one version of the block  32  has a face that is flush with line  33   b  and another version of the block  32  has a face that is flush with line  33   c . Therefore, if these two versions of the block  32  are used in the same wall, the wall has a multi-textured appearance. In other embodiments, a segmental wall may be made from blocks of one type and version, such as a standard block  32 , where the faces of the block are flush with each other, as they are stacked. 
   Next,  FIG. 3  shows a front view of the long horizontal block  32 . In this view, the front face  33   d  and top surface  33   e  of the block is shown in relation to the locking means  62 . Accordingly,  FIG. 4  displays a side view of the long horizontal block  32 . In this view, the locking means  62  is shown in relation to the front face  33   d  and a lateral alignment slot  95 . 
   As demonstrated in  FIG. 1 , another type of modular block used in an embodiment of the disclosure is a “long vertical block”  34  which may be utilized with the long horizontal block  32  to form a retaining wall  10 .  FIG. 5  shows a top view of an embodiment of the long vertical block  34 . As shown, the long vertical block  34  includes a side channel  94 , a locking means  64 , and a channel or lateral alignment slot  95 . A variety of faces of the block  34  may used to provide a different texture and design to the wall. In some embodiments, as represented by the dashed lines  35   b ,  35   c , the face of different versions of the block  34  may feature offset splits. In this way, a wall featuring the different versions of the block  34  will have a multi-textured appearance. 
   Next,  FIG. 6  shows a side view of the long vertical block  34 . In this view, the front face  35   d  of the block  34  is shown in relation to the locking means  64 , and lateral alignment slot  95 . 
   Further, another type of modular block used in an embodiment of the disclosure is a “half block”  36 . As shown in  FIG. 1 , the half block  36  may be used in a variety of patterns with the long horizontal block  32  and long vertical block  34  to form a modular retaining wall  10 .  FIG. 7  shows a top view of the half block  36 . As shown, the half block includes side channels  96 , locking means  66 , and a lateral alignment slot  95 . A variety of faces of the block  36  may used to provide a different texture and design to a modular retaining wall. As represented by the dashed lines  37   b ,  37   c , faces of different versions of the block  36  may feature offset splits, in some embodiments. 
   Next,  FIG. 8  shows a front view of the half block  36 . In this view, the front face  37   d  of the block is shown along with the locking means  66 . Accordingly,  FIG. 9  displays a side view of the half block  36 . In this view, the locking means  66  is shown in relation to the front face  37   d  and a lateral alignment slot  95 . 
   In some embodiments, a modular retaining wall block system may be made utilizing shapes of different size, shape, and depth. For example, a wall may be made using the standard  32 , vertical  34 , and half blocks  36  as illustrated in  FIG. 1 . To add additional texture to the wall, the blocks  30  may be made at different depths by utilizing different versions of the blocks with different offsets of the face. U.S. Pat. No. 7,390,146, entitled “MODULAR BLOCK STRUCTURES”, which is entirely incorporated herein by reference, describes modular block structures which may be utilized in modular retaining wall systems. 
     FIG. 10  illustrates an embodiment  20  of an anchoring system constructed in accordance with the present disclosure. In this particular example, a retaining wall  10  is constructed with, but not limited to, standard blocks  32  with a multi-split face. As shown most clearly in  FIG. 10 , a reinforcement member  1010  extends from the exterior surface  40  of the retaining wall  10  into a lateral alignment slot  95  of the wall blocks  30 , out from the interior surface  50  of the wall  10 , and into a portion of an embankment. In particular, the reinforcement member  1010  may comprise a geogrid material in a lattice arrangement that comprises fabric composed of a polymeric material such as polypropylene or high tenacity polyester. These reinforcement members  1010  typically extend rearwardly from the wall  10  and into soil of the embankment to stabilize the soil against movement and thereby create a more stable soil mass which results in a more structurally secure retaining wall  10 . In some embodiments, to secure the reinforcement members  1010  in the lateral alignment slot  95 , a portion of the reinforcement member  1010  is positioned within the lateral alignment slot  95  and secured in place by one or more retaining members  1120 . An optional configuration utilizing different blocks of different shapes and sizes and a random-like pattern, as shown in  FIG. 1 , is also able to utilize the geogrid anchoring system  20  utilizing retaining members  1120 , as described. 
   In accordance with the present disclosure, another embodiment of an anchoring system for securing a retaining wall is shown with respect to  FIG. 11 . In this example, the retaining wall  10  is secured in several predetermined points with tieback connections. As shown in  FIG. 11 , each tieback rod  1410  extends through an opening  1430  formed in the rear surface of its respective wall block  30  such that a proximal portion of the rod  1410  extends into a continuous elongated passageway  80 . Each of the tieback rods  1410  is secured in the earth of the embankment  1510  with conventional anchors (not shown). 
   As shown in  FIG. 11 , a tieback rod attachment mechanism  1520  (e.g., a steel plate) secures the tieback rod  1410  to the retaining wall  10 . The attachment mechanism  1520  normally includes an elongated force distribution member  1530  (e.g., rebar rod) that extends through a portion of the vertical height of the continuous elongated passageway  80  or column formed by the surrounding block  30 . Threaded onto each tieback rod  1410  is a conventional threaded fastener  1540  such as a nut which secures the attachment mechanism  1520  in position on the tieback rod  1410 , thereby securing the rod to the wall  10 . The continuous elongated passageway  80  is further encased in concrete after installation. The concrete with the blocks and the elongated force distribution member  1530  create a concrete reinforced beam that helps distribute the pressure from the earth anchor to the rest of the wall. U.S. Pat. No. 7,114,887, entitled “MODULAR BLOCK ANCHORING TECHNIQUES”, which is entirely incorporated herein by reference, describes anchoring systems for securing modular retaining wall systems. 
     FIG. 12  illustrates an embodiment of a modular block  1200  in accordance with the present disclosure. In accordance with the present disclosure, a variety of faces of the block may be used to provide a different texture and design to the wall. In this exemplary modular block  1200 , locking means  1262  are shown for securing another block positioned vertically atop the block  1200 . In this exemplary embodiment, locking means  1262  extend over the entire width of protrusions  1254  extending along the rear portion  1252  of block  1200 . The locking means  1262  includes an upper surface  1266 . As illustrated in  FIG. 11 , the locking means  1262  may be used to align ascending rows of blocks  30  ( FIG. 1 ). The width of locking means may be varied to provide different setbacks. Other geometric configurations such as, but not limited to, cylinders and geometric prisms may also be utilized for the locking means  1262 . While the embodiment of  FIG. 12  includes two locking means  1262 , other embodiments may include one or more locking means  1262  to align ascending rows of blocks  30 . 
     FIG. 13  illustrates the modular blocks  1200  of  FIG. 12  stacked  1300  for storage and/or transportation in accordance with the present disclosure. When stacked as shown in  FIG. 13 , a block  1200 ( a ) is supported by the top surface of block  1200 ( b ) and the upper surface  1266 ( b ) of locking means  1262 ( b ). To reduce damage to the locking means  1262  when the blocks  1200  are stacked, the upper surface  1266  of the locking means  1262  may be angled downwardly form rear to front. This angled arrangement can provide a larger area for force distribution and reduce the stress seen at the upper surface edges of the locking means  1262 . In one embodiment, voids are provided in the bottom surface of the block  1200  to receive the locking means  1266 . In some embodiments, surfaces of the void mirror the surfaces of locking means  1262 . Angling of the upper surface of the locking means may also be utilized on the long horizontal block  32 , the long vertical block  34 , and the half block  36  described above. 
   In the exemplary embodiment of  FIG. 13 , the angle of the upper surface  1266  of the locking means  1262  is aligned such that, when block  1200 ( a ) is placed on the upper surface  1266 ( b ) of locking means  1262 ( b ), the front edge of the bottom surface of block  1200 ( a ) rests on the top surface of block  1200 ( b ) as illustrated. The angle of the upper surface  1266 ( b ) is indicated by the line  1272  running from the rear edge of the upper surface  1266 ( b ) of locking means  1262 ( b ) to where the front edge of the bottom surface of block  1200 ( a ) rests on the top surface of block  1200 ( b ). In one embodiment, voids are provided in the bottom surface of the block  1200 ( a ) to receive the locking means  1262 ( b ). Other embodiments of angled locking means are illustrated in  FIG. 14 . 
   In the embodiment of  FIG. 14(A) , the angle of the upper surface  1266  of the locking means  1262  of a block  1200  is indicated by the line  1274 , which runs from the rear edge of the upper surface  1266  of locking means  1262  to where the front edge of top surface of block  1200 . Alternatively, in the embodiment of  FIG. 14(B) , the angle of the upper surface  1266  of the locking means  1262  of a block  1200  is indicated by the line  1276 , which runs from the rear edge of the upper surface  1266  of locking means  1262  to the rear edge of the lateral alignment slot  1295 . 
   In another embodiment illustrated in  FIG. 14(C) , the angle of the upper surface  1266  of the locking means  1262  of a block  1200  varies from the rear to the front of the locking means  1262 . In the embodiment of  FIG. 14(C) , the downward angle increases from rear to front of the locking means  1262 . As shown in  FIG. 14(C) , this produces a curved upper surface  1266 . The curved upper surface  1266  allows a block to be supported by a curved linear surface independent of its positioning on the lower block. The curved upper surface  1266  reduces the stress seen at the upper surface edge at the front of the locking means  1262 . 
     FIG. 15  shows an exemplary embodiment of a mold system for producing wall blocks of three different size, shapes, and depth. As shown, with a single mold  2200 , four standard or horizontal blocks  32 , two vertical blocks  34 , and four half blocks  36  are produced. Further, different versions of the blocks  32 ,  34 ,  36  are produced with a split offset to produce blocks of different depth. For example, a pair  2210  of half blocks  36  is arranged with each block positioned face to face. Therefore, after a concrete mixture is poured into the mold and set, the pair of blocks are split, in an offset manner, along the dashed line  2220  produce a “high” block  36 ( h ) and a “low” block  36 ( l ). This procedure is performed for each pair of blocks formed by the mold  2200 . By utilizing blocks produced from this mold  2200  in an undesignated pattern results in a multi-textured wall without a set pattern. Angling of the upper surface of the locking means  62 ,  64 ,  66  improves the molding process by reducing vacuum during head stripping of the mold  2200 . 
   Note that in an alternative embodiment, a mold  2300 , such as that represented in  FIG. 16  may be provided. Here, the locking means  62 ,  64 ,  66  or node on the rear portion of the block  2310  is enlarged and provided only on one side of a respective block. With this approach, the enlarged node may provide additional security in adjoining other blocks positioned above and also allow for flexibility in positioning neighboring blocks on the same tier or course. Reference characters are repeated in  FIG. 16  for corresponding parts that are also included in  FIG. 15 . Other combinations and/or configurations of locking means may be utilized in other embodiments. 
   It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiments of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure.