Building block having the appearance of wood shake

Various systems are provided for building blocks having the appearance of wood shake. In one embodiment, a building block includes first side body portion including a protrusion, a second side body portion including a recess configured to engage the protrusion of an adjacent building block, and a front body portion including a front exterior surface having vertical striated grooved lines configured to resemble a plurality of wood shakes; and a lower lip extending across the front exterior surface and extending below a lower surface. In another embodiment, a building block includes a front exterior surface having vertical striated grooved lines configured to resemble a plurality of wood shakes and a first side body portion including a side exterior surface having vertical striated grooved lines configured to resemble at least one wood shake and a lower lip extending across the front and side exterior surfaces and extending below a lower surface.

BACKGROUND

Traditional building materials for covering exterior surfaces of structures have included wooden shakes, clay tiles, and metal or wooden siding. These materials have enjoyed long standing acceptance in the building market, due both to their availability and attractiveness.

DETAILED DESCRIPTION

Disclosed herein are various embodiments of systems and methods related to building blocks. Reference will now be made in detail to the description of the embodiments as illustrated in the drawings, wherein like reference numbers indicate like parts throughout the several views.

Beginning withFIG. 1, shown is an example of a modular or segmental wall100in accordance with various embodiments of the present disclosure. Modular or segmental walls100commonly include courses or tiers of modular units or blocks. As depicted inFIG. 1, the wall100includes a plurality of building blocks103,106, and/or109having the appearance of wood shakes. The building blocks103,106, and/or109are stacked atop each other and together to form a façade or load bearing wall with an exterior surface112of the wall100having the appearance of wood shakes. Typically, the blocks103,106, and/or109are stacked in a staggered arrangement as shown inFIG. 1to provide greater stability to the wall100. Each building block103,106, and/or109may be bonded to one or more adjacent block103,106, and/or109by mortar, grout, or other adhesive at, e.g., the horizontal joint between courses and/or the vertical joints between blocks.

The building blocks103,106, and/or109are typically made of concrete using, e.g., molded manufacturing techniques to provide the vertical striated lines of the wood shake on at least one exterior surface of the block103,106, and/or109. For example, a dry cast vibratory machine can utilize molds to produce the design and shape of the building blocks103,106, and/or109. In some embodiments, the building blocks103,106, and/or109may be colored during manufacturing. In other implementations, the building blocks103,106, and/or109are colored on site. The size of the building blocks103,106, and/or109may vary within the standard sizes of the concrete products industry (e.g., ASTM C 55 and ASTM C 90). The building blocks103,106, and/or109include front and rear body portions connected by side body portions as will be discussed. The building blocks103,106, and/or109may include a celled unit construction with one or more void(s) or cavity(ies), which may be configured to accept rebar and grout to improve load bearing capabilities.

Referring next toFIGS. 2-4, shown is an example of a line building block103used in the modular wall100ofFIG. 1. As illustrated inFIG. 2, the line block103includes a front body portion203, a rear body portion206, and side body portions209connecting the front and rear body portions203and206. The front body portion203, rear body portion206, and side body portions209form a substantially planar lower surface212(as depicted inFIGS. 3-4) and a substantially planar upper surface215. The line block103includes one or more void(s) or cavity(ies) defined by the front body portion203, rear body portion206, and side body portions209. In the embodiment ofFIGS. 2-4, the line block103includes two voids or cavities218separated by a central body portion221connected between the front and rear body portions203and206. As illustrated in the cross-sectional views ofFIGS. 11 and 12, the sides1103and1203of a void or cavity218may taper outward from the upper surface215to the lower surface212. The taper is produced in the manufacturing process.

The front body portion203includes a front exterior surface224having vertical striated grooved lines configured to resemble one or more wood shakes. Variations may include different positions of the vertical grooves simulating the wood shake. For example, the striated grooved lines may be in a random configuration to simulate the appearance of a wood exterior shake. Separations between the striated grooved lines may also be provided to provide the appearance of a plurality of wood shakes. The front exterior surface224may extend outwardly from the top of the front exterior surface224(i.e., from the upper surface215) to the bottom of the front exterior surface224. In some implementations, a first portion of the front exterior surface224may extend out further than an adjacent second portion of the front exterior surface224to enhance the appearance of a plurality of wood shakes.

As shown inFIG. 3, the front body portion203also includes a lower lip227extending across the front exterior surface224and extending below the lower surface212. In the example ofFIGS. 2-4, the vertical striated grooved lines extend down the front exterior surface224from the upper surface215to the bottom of the lower lip227. As illustrated inFIG. 13, the extension of the lower lip227hides the horizontal joint1303formed between building blocks103,106, and/or109when stacked in courses. In addition, the lower lip227can hide bonding material (e.g., mortar, grout, or other adhesive) applied between the courses. In some embodiments, the lower lip227extends a uniform distance below the lower surface212. In other embodiments, a first portion of the lower lip227aextends a first distance below the lower surface212and a second portion of the lower lip227bextends a second distance below the lower surface212. As depicted inFIG. 4, the first portion227amay correspond to a first portion of the front exterior surface224that resembles a first wood shake and the second portion227bmay correspond to a second portion of the front exterior surface224that resembles a second wood shake.

As illustrated inFIG. 3, one side body portion209aincludes at least one protrusion230that protrudes from and extends down an end surface233aof the side body portion209a. In the example ofFIGS. 2-4, the line block103includes two protrusions230. As illustrated inFIG. 4, the other side body portion209bincludes a recess236corresponding to the protrusion230. The recess236recedes into and extends down an end surface233bof the side body portion209b. Connection between two building blocks103,106, and/or109may be achieved by aligning the protrusion(s)230of one block103,106, and/or109with the recess(es)236of an adjacent block103,106, and/or109, thereby engaging protrusion(s)230with corresponding recess(es)236to interlock the two blocks103,106, and/or109. In the embodiment ofFIGS. 2-4, the recess236and protrusion230have a trapezoidal cross-section as illustrated inFIGS. 9 and 10, respectively. Other cross-sectional shapes (e.g., circular, triangular or rectangular) may also be used as can be understood. In some embodiments, the protrusion(s)230and recess(es)236may be proportioned for manufacturing tolerances and to allow for bonding material (e.g., mortar, grout, or other adhesive) to be applied between adjacent building blocks103,106, and/or109.

Referring now toFIG. 5, shown is an example of a corner building block106used in the modular wall100ofFIG. 1. As with the line block103, the corner block106includes a front body portion203, a rear body portion206, and side body portions209connecting the front and rear body portions203and206. The front body portion203, rear body portion206, and side body portions209form a substantially planar lower surface212and a substantially planar upper surface215. The corner block106includes one or more void(s) or cavity(ies)218defined by the front body portion203, rear body portion206, side body portions209, and/or central body portion221.

The front body portion203includes a front exterior surface224having vertical striated grooved lines configured to resemble one or more wood shakes. The front body portion203also includes a lower lip227extending across the front exterior surface224and extending below the lower surface212. The front exterior surface224may extend outwardly from the top of the front exterior surface224(i.e., from the upper surface215) to the bottom of the front exterior surface224. A first portion of the front exterior surface224may extend out further than an adjacent second portion of the front exterior surface224to enhance the appearance of a plurality of wood shakes. In some embodiments, the lower lip227may extend a uniform distance below the lower surface212. In other embodiments, a first portion of the lower lip227extends a first distance below the lower surface212and a second portion of the lower lip227extends a second distance below the lower surface212.

In the embodiment ofFIG. 5, side body portion209bincludes a side exterior surface239having vertical striated grooved lines configured to resemble one or more wood shakes. The side body portion209balso includes a lower lip242extending across the side exterior surface239and extending below the lower surface212. The side exterior surface239may extend outwardly from the top of the side exterior surface239(i.e., from the upper surface215) to the bottom of the side exterior surface239. A first portion of the side exterior surface239may extend out further than an adjacent second portion of the side exterior surface239to enhance the appearance of a plurality of wood shakes. In some embodiments, the lower lip242may extend the same uniform distance below the lower surface212as lower lip227. In other embodiments, a first portion of the lower lip242extends a first distance below the lower surface212and a second portion of the lower lip242extends a second distance below the lower surface212. As illustrated inFIG. 5, the lower lip227extending over at least a portion of the front exterior surface224adjacent to the side exterior surface239and the lower lip242extending over at least a portion of the side exterior surface239adjacent to the front exterior surface224may extend the same distance below the lower surface212.

In the embodiment ofFIG. 5, the other side body portion209aincludes an end surface233athat is free of protrusions230or recesses236. In other embodiments, such as the corner block106illustrated inFIG. 1, the other side portion209aincludes at least one protrusion230that protrudes from and extends down the end surface233aof the side body portion209a. The rear body portion206includes at least one recess236. The recess236recedes into and extends down a back surface of the rear body portion206. As shown inFIG. 5, the recesses236are offset to align with the protrusions230of another building block103,106, and/or109, thereby aligning the side exterior surface239of the corner building block106with the front exterior surface224of the other building block. Connection between two building blocks103,106, and/or109may be achieved by aligning the protrusion(s)230of one block103,106, and/or109with the recess(es)236of an adjacent block103,106, and/or109, thereby engaging protrusion(s)230with corresponding recess(es)236to interlock the two blocks103,106, and/or109.

Referring next toFIG. 6, shown is another example of a corner building block109used in the modular wall100ofFIG. 1. The corner block109includes a front body portion203, a rear body portion206, and side body portions209connecting the front and rear body portions203and206. The front body portion203, rear body portion206, and side body portions209form a substantially planar lower surface212and a substantially planar upper surface215. The corner block109includes one or more void(s) or cavity(ies)218defined by the front body portion203, rear body portion206, side body portions209, and/or central body portion221.

The front body portion203includes a front exterior surface224having vertical striated grooved lines configured to resemble one or more wood shakes. The front body portion203also includes a lower lip227extending across the front exterior surface224and extending below the lower surface212. The front exterior surface224may extend outwardly from the top of the front exterior surface224(i.e., from the upper surface215) to the bottom of the front exterior surface224. A first portion of the front exterior surface224may extend out further than an adjacent second portion of the front exterior surface224to enhance the appearance of a plurality of wood shakes. In some embodiments, the lower lip227may extend a uniform distance below the lower surface212. In other embodiments, a first portion of the lower lip227extends a first distance below the lower surface212and a second portion of the lower lip227extends a second distance below the lower surface212.

In the embodiment ofFIG. 6, side body portion209aincludes a side exterior surface239having vertical striated grooved lines configured to resemble one or more wood shakes. The side body portion209aalso includes a lower lip242extending across the side exterior surface239and extending below the lower surface212. The side exterior surface239may extend outwardly from the top of the side exterior surface239(i.e., from the upper surface215) to the bottom of the side exterior surface239. A first portion of the side exterior surface239may extend out further than an adjacent second portion of the side exterior surface239to enhance the appearance of a plurality of wood shakes. In some embodiments, the lower lip242may extend the same uniform distance below the lower surface212as lower lip227. In other embodiments, a first portion of the lower lip242extends a first distance below the lower surface212and a second portion of the lower lip242extends a second distance below the lower surface212. As illustrated inFIG. 6, the lower lip227extending over at least a portion of the front exterior surface224adjacent to the side exterior surface239and the lower lip242extending over at least a portion of the side exterior surface239adjacent to the front exterior surface224may extend the same distance below the lower surface212.

In the embodiment ofFIG. 6, the other side body portion209bincludes an end surface233bthat includes at least one recess236. The recess236recedes into and extends down the end surface233bof the side body portion209b. The rear body portion206includes a back surface that is free of protrusions230or recesses236. In other embodiments, such as the corner block109illustrated inFIG. 1, the rear body portion206includes at least one protrusion230that protrudes from and extends down the back surface of the rear body portion206. As shown inFIG. 1, the protrusions230are offset to align with the recesses236of another building block103,106, and/or109, thereby aligning the side exterior surface239of the corner building block109with the front exterior surface224of the other building block. Connection between two building blocks103,106, and/or109may be achieved by aligning the protrusion(s)230of one block103,106, and/or109with the recess(es)236of an adjacent block103,106, and/or109, thereby engaging protrusion(s)230with corresponding recess(es)236to interlock the two blocks103,106, and/or109.

The building blocks103,106, and/or109ofFIGS. 2-6illustrate blocks used to form a load bearing wall. The size of the building blocks103,106, and/or109may vary within the standard sizes of the concrete products industry. For example, building blocks103,106, and/or109may be standard 8×8×16 blocks. As illustrated inFIG. 9, the recesses236may have a trapezoidal cross-section with an opening width903at the end surface233of about 1 inch, a depth906of about 0.25 inch, and side angles909of about 45 degrees. The protrusions230may be proportioned to take into account manufacturing tolerances and to allow for bonding material to be applied between adjacent building blocks103,106, and/or109. For example, as illustrated inFIG. 10, the protrusions130may have a trapezoidal cross-section with a width1003at the end surface233of about 0.938 inch, a depth1006of about 0.188 inch, and side angles1009of about 45 degrees. In the embodiments ofFIGS. 2-6, the protrusions230and recesses236may be spaced apart about 4.5 inches (center-to-center) for standard 8×8×16 blocks. Other shapes and sizes may be utilized as can be understood. In addition, in some embodiments, the front exterior surface224and/or side exterior surface239may extend about 0.5 inch from the upper surface215to the lower surface212with the lower lip227and/or242having a corresponding depth of about 0.5 inch.

Referring now toFIG. 7, shown is perspective view of the bottom of an example of a line building block303that may be used to form a building façade. As with the line block103, line block303includes a front body portion203, a rear body portion206, and side body portions209connecting the front and rear body portions203and206. The front body portion203, rear body portion206, and side body portions209form a substantially planar lower surface212and a substantially planar upper surface215. The line block303includes one or more void or cavity218defined by the front body portion203, rear body portion206, side body portions209, and/or central body portion221.

The front body portion203includes a front exterior surface224having vertical striated grooved lines configured to resemble one or more wood shakes. The front body portion203also includes a lower lip227extending across the front exterior surface224and extending below the lower surface212. The front exterior surface224may extend outwardly from the top of the front exterior surface224(i.e., from the upper surface215) to the bottom of the front exterior surface224. A first portion of the front exterior surface224may extend out further than an adjacent second portion of the front exterior surface224to enhance the appearance of a plurality of wood shakes. In some embodiments, the lower lip227may extend a uniform distance below the lower surface212as depicted inFIG. 7. In other embodiments, a first portion of the lower lip227extends a first distance below the lower surface212and a second portion of the lower lip227extends a second distance below the lower surface212.

One side body portion209aincludes at least one protrusion230that protrudes from and extends down an end surface233aof the side body portion209a. In the example ofFIG. 7, the line block303includes two protrusions230. As illustrated inFIGS. 7-8, the other side body portion209bincludes a recess236corresponding to the protrusion230. The recess236recedes into and extends down an end surface233bof the side body portion209b. Corner building blocks may also include elements as described with respect toFIGS. 5 and 6. Connection between two building blocks may be achieved by aligning the protrusion(s)230of one block with the recess(es)236of an adjacent block, thereby engaging protrusion(s)230with corresponding recess(es)236to interlock the two blocks.

Referring toFIG. 8, shown is a bottom view of the building block303ofFIG. 7. The size of the building block303and associated corner blocks may vary within the standard sizes of the concrete products industry. For example, building block303may be standard 4×8×16 block. As illustrated inFIG. 9, the recesses236may have a trapezoidal cross-section with an opening width903at the end surface233of about 1 inch, a depth906of about 0.25 inch, and side angles909of about 45 degrees. The protrusions230may be proportioned to take into account manufacturing tolerances and to allow for bonding material to be applied between adjacent building blocks. For example, as illustrated inFIG. 10, the protrusions130may have a trapezoidal cross-section with a width1003at the end surface233of about 0.938 inch, a depth1006of about 0.188 inch, and side angles1009of about 45 degrees. In the embodiments ofFIGS. 7-8, the protrusions230and recesses236may be spaced apart about 2 inches (center-to-center) for standard 4×8×16 blocks. Other shapes and sizes may be utilized as can be understood. In addition, in some embodiments, the front exterior surface224and/or side exterior surface239may extend about 0.5 inch from the upper surface215to the lower surface212with the lower lip227and/or242having a corresponding depth of about 0.5 inch.

WhileFIG. 8shows building block303ofFIG. 7, the building block features ofFIG. 8are equally applicable to the building blocks103,106, and/or109ofFIGS. 2-6. For example, the building blocks103,106, and/or109and building block303may utilize the same dimensions for protrusions230and recesses236as illustrated inFIGS. 9 and 10. In addition, as illustrated in the cross-sectional views ofFIGS. 11 and 12respectively, the sides1103and1203of the void or cavity218may taper outward from the upper surface215to the lower surface212. In some embodiments, the central body portion221may include a further extension1106that protrudes into the void or cavity218at the upper surface215as illustrated inFIG. 11.

Referring next toFIG. 13, shown is a cross-sectional view illustrating the stacking of the building blocks, such as blocks103,106,109, and/or303ofFIGS. 1-7, in accordance with various embodiments of the present disclosure. The building blocks are stacked atop each other in courses or tiers and together to form a façade or load bearing wall. As illustrated inFIG. 13, the extension of the lower lip227hides the horizontal joint1303formed between building blocks when stacked in courses. Each building block may be bonded to one or more adjacent block by bonding material (e.g., mortar, grout, or other adhesive) at, e.g., the horizontal joint1303between courses. The lower lip227can also hide the bonding material applied between the courses.