Interlocking masonry unit

A multi-purpose interlocking masonry unit includes support members extending from its lower surface and port depressions formed in its upper surface. Each masonry unit can be placed on top of a previously placed masonry unit. The interlocking masonry unit allows for the rapid creation of a wall that is substantially straight and aligned while minimizing the need to perform precise measurements and make alignment adjustments during the creation process. Bonding material can be poured through the resultant wall ports, creating a matrix pattern of bonding material throughout the wall, which results in a stronger more durable construction.

FIELD OF THE INVENTION

The present invention relates to an interlocking masonry unit. One embodiment of the invention comprises an interlocking masonry unit for use in mortared or similar wall construction which reduces the need for constant measurements and alignment, resulting in a wall with increased strength.

BACKGROUND OF THE INVENTION

The creation of buildings by utilizing walls made of concrete or similar stonework is a popular method of construction. Many traditional masonry walls are created using masonry units commonly referred to as cinder blocks. A cinder block is a masonry unit in the shape of a rectangular prism with two vertical chambers. A wall is constructed by creating successive rows of cinder blocks. Often each row of cinder blocks is offset by half a block from the previous row to increase stability. Some form of mortar or similar bonding material is placed between each row of blocks to bond the blocks into a solid structure.

One of the primary difficulties of creating cinder block walls is that constant measurements and adjustments must be made as the construction process is undertaken. Bonding material must be laboriously applied between each new block and all adjacent blocks. The craftsman must constantly adjust the wall as each block is placed to ensure that each row is level and straight. Failure to make constant adjustments often results in a wall that is uneven, non-level, angular, or otherwise unstable and not ascetically pleasing. This process is both time consuming for the craftsman and subject to significant human error. The resulting wall is also only as strong as the weakest bonded joint between two adjacent blocks.

Accordingly, there is a need for an interlocking masonry unit. The interlocking masonry unit should connect with adjacent masonry units in a standard way that reduces the need for precision and skill. The interlocking masonry unit should also be designed to accept bonding material that is poured into the wall after each course of the wall is completed in order to reduce overall construction time. The interlocking masonry unit should also be designed to allow the bonding material to pour inside of and between the masonry units in both the horizontal and vertical dimensions to create a strong wall that is bonded together internally in all directions forming a matrix. Furthermore, other desirable features and characteristics of the present invention will become apparent when this background of the invention is read in conjunction with the subsequent detailed description of the invention, appended claims, and the accompanying drawings.

SUMMARY OF INVENTION

An object of the present invention is to provide an interlocking masonry unit that can overcome the aforementioned deficiencies. One embodiment of the invention comprises an interlocking masonry unit that can be placed in connection with an adjacent masonry unit in a standard manner that reduces the need for constant measurement and adjustment for alignment purposes. Bonding material can be poured as the wall is created so that the need for adjustment is clear to the craftsman before the units become permanently bonded together. The interlocking masonry unit can include both horizontal and vertical cavities to accept bonding material in order to create a matrix of bonding material to increase the overall strength of the wall.

DETAILED DESCRIPTION OF INVENTION

An interlocking masonry unit according to a preferred embodiment of the invention is illustrated inFIGS. 1 and 2, and is shown generally at reference numeral100.FIG. 1illustrates a perspective view of the concave upper surface and a side surface of the masonry unit100. The masonry unit100comprises a generally rectangular prism shape with a concave upper surface10as shown inFIG. 1. a concave lower surface20as shown inFIG. 2, two side surfaces11as shown inFIG. 1, and two end surfaces30as shown inFIG. 3. The masonry unit100can be made of traditional masonry material, such as concrete. Alternatively, the masonry unit100can be made of foam. One skilled in the art will recognize that any three dimensional object with a rectangular prism shape generally comprises six surfaces. The surface names, as used throughout the application, are chosen for purposes of designation rather than functionality and should not be considered limiting. The purpose of the concave shape of the upper surface10and lower surface20is discussed below in reference toFIG. 3.

The masonry unit100comprises one or more central vertical cavities12, as shown inFIGS. 1 and 2. The central vertical cavities12should extend between the lower surface20and the upper surface10of the present invention and should be capable of accepting bonding material. In the preferred embodiment, two central vertical cavities12are employed, and each of the central vertical cavities12comprise the same shape mirrored about an axis passing through the center of the unit and perpendicular to the side surfaces11. In the preferred embodiment, the central vertical cavities12comprise a rounded triangular shape, however, many central vertical cavity12shapes could be substituted. When two or more interlocking masonry units100,100′ are placed in a vertically adjacent position relative to one another, also referred to hereinafter as a stack as shown inFIG. 3, the central vertical cavities12of each masonry unit should be generally aligned with the central vertical cavities12of the other units. So long as the central vertical cavities12of each unit are generally the same shape and are generally aligned, any bonding material poured into a central vertical cavity12of the uppermost unit100will also pour through the corresponding central vertical cavity12of each unit below in the stack due to the force of gravity. This allows a craftsman to quickly create a wall by stacking the masonry units, one on top of one another, and then pouring bonding material through each vertical cavity as the wall is completed and judged to be in the proper shape and alignment. In the preferred embodiment, the central vertical cavities12are surrounded by a sloped edge12A as shown inFIGS. 1 and 2, preferably at or near a forty five degree angle from the horizontal plane, to act as a funnel creating a larger void between the upper and lower masonry units, thus assisting the bonding material in its movement into the lower portions of the stack.

As shown inFIG. 2, the masonry unit100comprises a plurality of support members21projecting vertically out from the lower surface20of the masonry unit. Preferably, eight support members21are employed, however, a greater or fewer number of support members21can be employed. As shown inFIG. 1, the masonry unit comprises a plurality of receiving port depressions13each projecting vertically into the upper surface10of the masonry unit100. Preferably, eight receiving port depressions13are employed. Each receiving port depression13can be shaped and positioned to be capable of receiving a corresponding support member21from another masonry unit. As such, multiple masonry units can be stacked one on top of another. When creating the stack, the support members21of the upper masonry unit are received by the receiving port depressions13on the upper surface10of the masonry unit immediately below it. In this manner, each masonry unit is effectively interlocked into position relative to the masonry units below. Absent manufacturing defects or variable terrain, the resulting stack is straight and level without requiring the user to undertake efforts to adjust or otherwise level the stack. As variable terrain and manufacturing irregularities are possible, the user can rapidly create a stack and quickly observe and correct any alignment concerns prior to pouring bonding material through the vertical cavities. Preferably, each receiving port depression13is larger than the support members21to allow the user to make minor adjustments to the wall as it is completed.

In a preferred embodiment, each end surface30as shown inFIG. 3further comprises two end projections14. As shown inFIG. 4. the end projections14can be shaped and positioned so that when two interlocking masonry units are placed in a horizontally adjacent configuration, an intermediate vertical cavity40, as shown inFIG. 4, extending between the masonry units is created. When the masonry units are stacked in rows, the intermediate vertical cavity40can accept bonding material. So long as the masonry units are not offset, the bonding material can be capable of poured through an intermediate vertical cavity40, as shown inFIG. 5, that is placed in a higher position in the stack to intermediate vertical cavities40that are placed lower in the stack due to the force of gravity. However, even in an offset configuration, as can be seen inFIG. 5, the bonding material can be poured into each intermediate vertical cavity40from the central cavity12above it, due to the shape and positioning of the central cavities12. Each of the end projections14include a sloped edge14A, as shown inFIG. 1, preferably at or near a forty five degree angle from the horizontal plane, to act as a funnel and assist the bonding material in its movement into the lower portions of the stack. The end projections14should be omitted on the end surface30of any masonry unit that is to be used at the corner of a wall. It should also be noted that, in the preferred embodiment, portions of each block end come in contact with an adjacent block. This allows for proper alignment and spacing which maximizes amount of bonding material to attach between each unit to strengthen the bond. It should also be noted that, preferably, the shape of the intermediate vertical cavity40is irregular. This configuration increases the surface area available for the bonding material to attach to for a stronger bond. This configuration also ensures that the end projections14each attach around the cured bonding material contained in the vertical cavity40, which further reduces the possibility of a breach in the wall, even if the bonding material should become separated from the associated masonry unit.

As shown inFIGS. 1 and 4, the masonry unit100can include one or more vertical depressions15in one or both of the side surfaces11. Preferably, each vertical depression15has a width greater than one-half inch and less than two inches. Preferably, each vertical depression15projects into the masonry unit100between one-half inch and two and a half inches, and each vertical depression15also preferably extends down the entire side surface11of the masonry unit. When crafted to these preferred dimensions, each vertical depression15is capable of accepting a wall stud. The vertical depressions can further comprise a plurality of stud support notches17, as shown inFIGS. 1 and 2. Each of the stud support notches17can be capable of accepting a peg to hold a wall stud in place. When a wall is finalized, a wall stud can be inserted into the vertical depression15and secured in position by means of plurality of pegs or similar items hammered or screwed into the stud support notches17. In an alternate embodiment, no support notches17are provided and the wall studs can be secured by a toggle bolt or other securing means. This allows the user to create a wooden wall, capable of accepting drywall or similar finishing material without the structure that is typically associated with a standard wall. Referring toFIG. 4, the end projections14may also be shaped and positioned to create a vertical depression15in the side surface11between two horizontally adjacent interlocking masonry units100,100′ that are capable of accepting a wall stud. This ensures that in the case of stacked rows where one or more rows are offset by half a masonry unit from one another, the vertical depression15in the side surface11of a masonry unit lines up with the vertical depression15created between two horizontally adjacent masonry units on a different row. This allows a wall stud to be accepted into all of the rows at once. Preferably, the vertical depressions15are positioned to create a distance of eight inches between the center of each wall stud and the center of the horizontally adjacent wall studs, once said wall studs are accepted. This allows the user to easily attach standard building materials to the wall studs.

FIG. 3illustrates an end plan view of two vertically adjacent interlocking masonry units100,100′. In the preferred embodiment, the concave upper surface10of the lower masonry unit and the concave lower surface20of the upper masonry are shaped to create a horizontal cavity31which extends between the two masonry units. The horizontal cavity31is capable of accepting bonding material poured from upper rows through the vertical cavities and channeling the bonding material horizontally between two rows in the wall. The channel created by the horizontal cavity31and the vertical cavities12create a matrix of cured bonding material which increases the overall strength of the wall in relation to standard cinderblock walls. The channel created by the horizontal cavity31also allows bonding material to pour into the intermediate vertical cavities40in cases where the rows of the wall are offset. An end surface30of any masonry unit that is to be used at the corner of a wall can include an additional projection on the upper surface10and the lower surface20capable of closing the horizontal cavity31and vertical cavity40preventing any bonding material from escaping from the channel created by the horizontal cavities31of the masonry units100,100′ in the wall.

In a preferred embodiment, the upper surface10further comprises a plurality of upper projections32as shown inFIG. 3. The upper projections32can accept one or more reinforcing elements16, as shown inFIG. 1andFIG. 5, such as concrete reinforcing bar, also known as rebar, and/or similar items. The vertical channels created by the central vertical cavities12are also capable of accepting one or more reinforcing elements16. The presence of the reinforcing elements16increases the overall structural integrity of the resultant wall after the bonding material is poured inside and allowed to cure. The matrix of vertical and horizontal channels associated with a wall constructed with the interlocking masonry units, as described herein, along with associated reinforcing elements16, creates a structural integrity that is significantly increased over a standard cinder block wall.

In a preferred embodiment, the masonry unit100has sharp edges14,35at the outer perimeter at the top and bottom and on both ends of the masonry unit100, as shown inFIGS. 1 and 2. The sharp edges14,35form one-half of a mortar seam. The edges14,35slope inward, toward the center of the masonry unit100to form a “V” or pinch point37,45, as shown inFIGS. 3B,4and8, between masonry units100,100″, when the units are stacked end to end and/or one on top of the other. The pinch points37,45preferably should be approximately one-sixteenth to one eighth inch in width. The pinch points37,45are shaped similar to a funnel to guide the bonding material from a wide area or space to the narrow space where the grit, sand and gravel of the bonding material fill in, forcing out air from the masonry units and sealing the space, bonding the units together. In addition, the masonry unit100can have sloped, concave outer edges34, as shown inFIG. 3.

In a preferred embodiment, each end projection14further comprises a bumper projection33. As can be seen inFIG. 4, each bumper projection33is shaped and positioned to come in contact with a bumper projection33of an equivalent horizontally adjacent interlocking masonry unit when the masonry units are being placed by the user. In this manner, the user may place each masonry unit, verify the bumper projections33of each masonry unit are properly touching, and thereby verify that the row of masonry units being created is level and aligned. The bumper projections33hold the blocks of the masonry units apart a pre-determined distance, as shown at reference numeral45inFIG. 4. Preferably, the bumper projections33create a space45of approximately one-sixteenth to one-eighth inch wide. This space45lets the air out when the masonry units are being filled with bonding material. The grit, rock and sand that is part of the bonding material fills the internal block voids are stopped from exiting at this point

FIG. 5illustrates a perspective view of a wall comprising multiple masonry units according to a preferred embodiment of the invention. A method of assembling a wall comprising interlocking masonry units as depicted inFIG. 5is now more fully described. A row of interlocking masonry units can be created by placing a plurality of interlocking masonry units on a prepared surface in a manner that causes the end surface33of each masonry unit to come in contact with an end surface33of one or more adjacent masonry units. Subsequent rows of interlocking masonry units can be positioned on top of the previously created row of interlocking masonry units by placing the support members21of the masonry units in the subsequent row into the receiving port depressions13of the previously placed row. This process can be repeated until a wall or structure of the desired height is created. Reinforcing elements16can be placed into the horizontal cavities31between each row. Depending on the embodiment, the user may shift each subsequent row by half of the length of a masonry unit in the horizontal axis from the previously placed row to increase the stability of the resultant wall. The reinforcing elements16can be placed in the horizontal cavities31prior to placing any associated corner units. Reinforcing elements16should also be placed into the central vertical cavities12and40of each masonry unit for greater structural integrity. Bonding material can be poured into the vertical cavities and allowed to spread and seep into the horizontal cavities to create a matrix of bonding material throughout the cavities of the wall. A mechanical means may be employed to vibrate and to assist the bonding material in its spread throughout the matrix of cavities in the structure. The bonding material should then be allowed to cure in the wall. In an alternate embodiment, bonding material can be poured into the cavities after each row is positioned.

The support members21can serve a number of purposes. The support members21can align the upper block200and the lower block300with each other. Also, the support members21lift or hold the block200above the lower block300, as shown inFIG. 8. Preferably, the support members21are about 1/16 to ⅛ inch longer than the members21would be when positioned in the port depressions to align the upper block200and lower block300the outer horizontal sides or edges to sit flat or flush against each other. The support members21keep the block200raised off the outer edges of the block300below it creating an air gap37, shown inFIG. 8, between the upper block200and the lower block300, as shown inFIG. 8. The outer edge of the upper block and lower block has a molded in mortar seam, as shown inFIG. 3, on each horizontal edge34of the block next to or adjourning the horizontal edge of the block where the molded in mortar seams run horizontally at the back top edge. Starting from the top front edge of the mortar joints or seam, this is where the gap37is formed and mortar fills the gap between the blocks to seal and bond the blocks together. The surfaces of the back top edge begin to slope or taper off inward to the concave surface. This sloping edge runs the horizontal length of the block, and the inward sloping mortar joint goes around the outer edge of the vertical cavities15, as shown inFIG. 1.

This inward sloping taper of the back of the mortar joint or seam can be on both edges of the block, top and bottom. When the top block support members21are positioned in the bottom block port depressions, the horizontal edges between the two blocks are separated by a space or an air gap by approximately 1/16 to ⅛ of an inch. This space has the purpose of exhausting of the air as the block is filled with bonding material. The support members21hold the blocks apart about 1/16 to ⅛ of an inch support and align the block. The support members21holding the blocks apart leave a gap or space between the blocks. When bonding material flows into the vertical cavities12,40, bonding materials also flows into the horizontal concave cavities31and the blocks become filled with bonding material in vertical cavities12,40and the horizontal concave cavities31. Bonding material forces air out through this space or air gap between the blocks, filling the space between the blocks with bonding material. The bonding material continues to seep into the space, sealing the space, filling out the mortar seam, surrounding the support members filling the horizontal concave space or voids and the vertical spaces allowed to cure the blocks will not separate without destroying the assembly.

As shown inFIG. 4, an air gap45is created vertically between the two blocks end when the blocks are placed in close proximity to one another. The air gap45is approximately 1/16 to ⅛ of an inch wide.

The front top edge of the one half mortar seam begins to slope or taper off to the interior. The top edge of the one half mortar seam is a vertical pointed area. When the two blocks with the same pointed area come together they form a pinched point45as shown inFIG. 4(also see reference numeral37inFIGS. 3B and 8).

When the ends of two blocks come together and are aligned, and the bumpers or spaces touch properly, the vertical cavity40is formed. When the bonding material fills the cavity, it pushes air out through the air gap45, as shown inFIG. 4, since the opening forming the air gap tapers down to 1/16 to ⅛ of an inch between the two half mortar seams. Bonding material cannot go through the gap45. The bonding material bonds and seals the air gap45creating a finished mortar seam or joint. As shown inFIG. 4, the block ends are kept apart by the bumper33or spaces located on each end. The purpose of the bumpers33or spaces is to keep the blocks the proper space or distance apart so that no other part of the block touches the other. The bumper or spacers touch at a predetermined point at its outer edge. This keeps the blocks properly spaced apart and aligned with the other block so that there is an air gap45, shown inFIG. 4, at the vertical ends of the block.

The vertical channels12,40, shown inFIG. 4, increase the flow of bonding material between both blocks when the blocks are offset. An extra wide void31, shown inFIG. 3, is created in the concave horizontal design of the block. The concave is extra wide and deep to increase the bonding flow and more adhesive surfaces. The void is concave on the upper blocks, lower or bottom surface, and concave on the lower blocks upper surface. The concave surfaces can accomplish several things. The concave surfaces open up or increase the open space or void between the upper and lower blocks, increase the amount of surface area the bonding material can attach to and increases the ease whereby the bonding material can flow between blocks to fill open spaces or voids, and increase or enhance the flow of bonding material over or through the vertical cavities12.

The vertical cavities12,40can have angled or sloped top edges51, as shown inFIG. 3A. The angle or slope on the top edge of the vertical cavities12,40are cut away at an angle of about thirty to forty-five degrees to enhance or increase the flow of the bonding material through the vertical cavities12,40and concave spaces and/or voids. The top sloping edges51and bottom sloping edges50of the vertical cavities12,40, of the block add to the overall surface area for bonding material to attach to for added adhesion or bonding surface for added strength of the structure. In addition, the sloping edge forms a locking plug in the vertical cavities so if the bonding materials become detached from the vertical cavities the overlap or lock formed by the cured bonding material lapping over the edge or sloping outward from the vertical cavities12, shown inFIGS. 1 and 2, lock the plug into the vertical cavities by virtue of the lip or the slope. Therefore, when the wall structure is built the bonding materials form a matrix or lattice in the interior of the block. If a horizontal or vertical force is applied to the wall, the wall resists movement because of the matrix or lattice in the interior cured bonding material and the rebar structure.

The bonding material surrounds all support members21to hold them in place. The upper and lower concave areas of the two blocks are bonded together by the bonding materials that fill the connected spaces. The upper and lower blocks are bonded together through the bonding materials in the vertical cavities. The studs in the vertical cavity15, shown inFIG. 1, help support the wall. The studs can be locked in each block by pegs or similar devices to keep it from moving vertically or horizontally. The lips or slopes (angles)12A,14A keep the block from pulling apart vertically.

The introduction of the rebar between the upper and the lower block with their ends tied together adds strength to the matrix of the cured bonding material that runs within the interior of the structure. The bonding material matrix within the block and the vertical rebar in the vertical structure in combination with the two rebar that run across the blocks top center rebar supports16,32, shown inFIGS. 1 and 3, add to the durability, strength, and integrity of the structure holding the blocks together both horizontally and vertically.

The point of the vertical triangular cavity12points inward between support members21, as shown inFIG. 2, to extend far enough into the center of the block to be over the opening of the cavity40. The blocks are offset by one half block for cavity40to be fully filled with bonding material, since the opening between cavity12and cavity40vertically is narrow.

So that there are the minimum number of unbonded surfaces within a structure, an air gap52can be made around the support member21, as shown inFIG. 6. As shown inFIG. 6, the support member21can be seated loosely, for slight movement in the port depression13. The upper part of the support member at the concave surface54has a large air gap around the support member21. This air gap allows bonding material to flow down into the port depression along the sides of the support member21inside the port depression bonding everything together in the concave surface.

In order for bonding material to flow more easily into cavity40, which is below the rebar bridge, when the masonry units are offset by one-half masonry unit, the triangular shaped vertical cavities12on both ends of the masonry unit have been cut down or cut away, as shown inFIG. 3Aat reference numerals50and51. This feature, in addition to the feature shown inFIG. 2at reference numeral12B increases the volume of flow of bonding material below the rebar bridge to cavity40.FIG. 4Aprovides a reverse view, in which the shaded area which is normally below the rebar bridge is shown on top for the purpose of showing the limited space between the masonry unit for bonding material to flow into cavity40when the rebar bridge is above. The white area shown at reference numeral47inFIG. 4Ashows the limited opening to the cavity40below the rebar bridge area limiting bonding material flow to cavity40below.

Filling cavity40can be a problem, because of the rebar support bridge. The bridge adds strength to the center of the block and gives the wall integrity. The width of the center of the block and the position of cavities12over cavity40can make it necessary to use an enhanced triangular shaped vertical cavity with a cutaway section12B on the bottom of the block, as shown inFIG. 2.

The width between the two support members21, shown inFIG. 2, where the triangular shape vertical cavity points to the center of the block has limited opening. To overcome the narrowed opening to cavity40, the triangular shaped cavity is used to extend between support members21, as shown inFIG. 2at reference numerals12,12B. This creates a larger opening to the vertical cavity40below on both sides of the rebar support bridge, shown inFIG. 3at reference numeral32.FIG. 4Ashows a reverse view with cavity40on top for the purpose of showing the limited opening to cavity40below the rebar bridge. The cavity40is below the rebar bridge32, shown inFIG. 3, for this purpose. Looking down along both sides of the rebar bridge, only the area47(shown inFIG. 4Ain white) of cavity40can be seen from above the rebar bridge. This shows the narrow opening to cavity40below.

As shown inFIG. 2, the concave area between the upper and lower block and the position of the triangular vertical cavity12and the cutaway area12B gives the cavity40spanned between the two blocks a wider opening for bonding material to flow through.

The cutaways12B are widening inward protruding point of the triangular vertical cavity12, as shown inFIG. 2, enhances the flow of bonding material to vertical cavity40, as shown inFIG. 4A, which is a reverse overlay. The cutaway are12B widening and increasing the opening between the cutaway point of the triangular vertical cavity12and cutaway12B on the bottom of the block, opening up the horizontal concave cavity to vertical cavity40below.

As shown inFIG. 1, the vertical cavity15adds to the overall durability, strength, and integrity of the structure. The two by four or other structure having been locked into the vertical cavities15by the peg system resists being pulled out vertically or horizontally, thereby maintaining the structure.

When cavity40is over the blocks rebar support, the problem of bonding material flow is lessened by the fact that vertical cavities12on either side of cavity40has a wide opening to the vertical cavities below the block and can be easily filled. When the rebar support area is offset by one half block vertical cavity40opening or passage way between the upper block vertical cavity12and the lower block vertical cavity40is greatly narrowed.

To overcome the narrow passage way that the bonding material has to go through, the opening should be opened up greatly. To do this, the vertical triangular opening12, shown inFIG. 2, should be between the support members21and pointed inward toward the center of the block. Next, the concave surface on the top of the block and the bottom of the block had to be as deep as possible.

To accommodate the fast flow of the bonding material for maximum opening of the upper and lower block. Next, the edges of the cavities12and40had to be opened up or widened to create a larger gap between the lower vertical cavity12edge of the top block and the top edge of the vertical cavity of the bottom or lower block. To do this, the edges of the vertical opening12A and14, shown inFIG. 1, are trimmed back to a thirty to forty-five degree angle or slope. With the sloping edges of the vertical cavities and a distance between 2½ to 3 inches maximum between the upper and the lower concave surfaces bonding flow is increased.

The opening between the upper block vertical cavity12and the lower block cavity40can be opened up or widened further by cutting away part of the center of the block, as shown inFIG. 2at reference numeral12B. The cutaway of the center of the block gives more opening or space between the upper block vertical cavities12and the lower vertical cavity40, thus the bonding material has a greater opening for bonding material to flow through to fill the cavities.

When the blocks are offset by one half block, the rebar support area is shifted to be over the vertical cavity40, as shown inFIG. 4A. This reduces the opening between vertical cavity12and the vertical cavity40in the block below.

The triangular shape vertical cavity12enhances the flow of bonding material in the vertical cavities12and40. The edges on the concave surfaces of the block can be cut deeply, such as at a thirty to forty-five degree angle as shown inFIGS. 1 and 2at reference numerals12A,14A. The lip or slope of the edge of the cavities on the top concave surface and the bottom concave surface prevent the cured bonding material from pulling out.

The triangular shape of the vertical cavities should be pointed inward toward the center of the block to be able to reach in far enough to be over cavity40, as shown inFIG. 4Aat reference numeral47.FIG. 4Aprovides a reverse image with cavity40on top of the rebar area, and area47(shown in white inFIG. 4A) being the opening to the cavity40below.FIG. 4Ashows cavity40on top to illustrate the narrow opening to vertical cavity12.

An extended area of the lip or slope inward to the center of the block area can be cutaway, as shown inFIG. 2at reference numeral12B. This area opens up or widens the distance or space between vertical cavities40and the cavity12and area12B. This cutaway area12B gives the bonding material a bigger opening to flow through. Also, the triangular shape gives the vertical cavity12a wider opening in the concave cavity, as shown inFIG. 2. The outer edges of the triangular shape and sloping lip extended between and beyond the mounting area of the support members21gives the horizontal cavity a wider opening in the concave cavity for bonding material to flow through to cavity40. The interior of the vertical cavities12can have rounded corners or points, since sharp angles have a greater tendency to crack or break. The maximum amount of material has been removed from the block without sacrificing the structural integrity of the block. As such, the area for the bonding material to attach to is maximized, thereby making the block lighter and minimizing the amount of material needed in the manufacturing process.

When two block ends come together, each forms one half of the vertical cavity40, as shown inFIG. 4. The end vertical cavity of a block is one half part of vertical cavity40, and has a locking design in that the horizontal opening is narrower, as shown inFIG. 4at reference numeral42, than the back side open vertical area. The cavity40includes an area14A on the upper and lower lip or edges of the vertical cavities40. When the end of the two blocks are placed together, as shown inFIG. 4, and bonding material fills the area and is allowed to cure, the blocks become inseparable. The cured bonding material cannot pull out vertically, because the bonding material overlaps the slope of area14A, as shown inFIG. 1. Also, the bonding material cannot pullout of the vertical cavity40, because it is locked in the vertical cavity40by the vertical lip and narrow opening, as shown inFIG. 4at reference numeral42.

While the present invention has been described above in terms of specific embodiments, it is to be understood that the invention is not limited to the embodiments described above. Various modifications and other embodiments can be made without departing from the scope of the present invention. The foregoing description of various embodiments of the invention and the 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 following claims and equivalents thereof.