Continuous chamber environment resistant retaining wall block and methods of use thereof

The present invention relates to a retaining wall block that is resistant to damage and wear caused by the environment and includes a chamber, which allows the flow of fill material to adjacent blocks below and above. The deterioration resistant block is generally a hollowed frame or shell of a deterioration resistant material that is light-weight and is configured to interlock with adjacent blocks, thereby forming a continuous chamber capable of accepting and retaining any type of filling material. The filling material provides weight, stability and security to a retaining wall constructed of such blocks.

FIELD OF THE INVENTION

The present invention relates to a retaining wall block that is resistant to damage and wear caused by the environment and includes a chamber, which allows the flow of fill material to adjacent blocks below and above. The deterioration resistant block is generally a hollowed frame or shell of a deterioration resistant material that is light-weight and is configured to at least partially align with blocks positioned above and below, thereby forming a continuous chamber capable of accepting and retaining any type of filling material. The filling material provides weight, stability and security to a retaining wall constructed of such blocks.

BACKGROUND OF THE INVENTION

The use of retaining walls to protect and beatify property in all types of environmental settings is a common practice in the landscaping, construction and environmental protection fields. Walls constructed from various materials are used to outline sections of property for particular uses, such as gardens or flower beds, fencing in property lines, reduction of erosion, and to simply beautify areas of a property.

Numerous methods and materials exist for the construction of retaining walls. Such methods include the use of natural stone, poured in place concrete, masonry, landscape timbers or railroad ties. In recent years, segmental concrete retaining wall units, sometimes known as keystones, which are dry stacked (i.e., built without the use of mortar), have become a widely accepted product for the construction of retaining walls. Examples of such units are described in U.S. Pat. No. RE 34,314 (Forsberg) and in U.S. Pat. No. 5,294,216 (Sievert).

However, many of the materials utilized in the construction of retaining walls are susceptible to deterioration and/or are not very aesthetically appealing. The ability of these retaining walls to withstand sunlight, wind, water, general erosion and other environmental elements is a problem with most retaining wall products.

A particular concern is the utilization of erosion protection materials in water shorelines. Leaving the shoreline natural can lead to erosion, cause an unmanageable and unusable shoreline, create high maintenance, and inhibit an aesthetically pleasing property. Many materials utilized in retention of shorelines are subject to immediate deterioration and/or are not as aesthetically appealing as one would desire. Furthermore, many materials utilized on shoreline structures are difficult to maintain due to the awkward location in the water and also the prevalent growth and presence of organic materials that can get caught and flourish in such a structure. For example, many lakeshore or ocean side properties utilize riprap as a retention device for prevention of erosion. Riprap is a configuration of large to medium size stones placed along the shoreline. A problem with waterfront properties that use a continuous wall of typical riprap is the shoreline will retain some organic material or will accumulate additional organic material brought in by the water. This usually leads to an unmanageable and aesthetically displeasing shoreline or higher maintenance. Furthermore, the riprap is never uniform in color and size and therefore does not as provide the most aesthetically pleasing shoreline or complete coverage of the shoreline. The lack of uniform shoreline coverage allows for some erosion, collection of various materials and the growth of weeds.

Another problem with materials normally utilized in the construction of retaining walls, such as poured in place concrete, masonry, landscape timbers, railroad ties or keystones is that regulations in most states and counties prohibit their use in or near bodies of water because of the crumbling or deterioration of the material into the body of water over time or the leaching of chemicals from the materials into the body of water. Many of these retaining wall materials dissolve, crumble, break apart and/or float into the body of water for which they line causing problems with the shoreline and pollution of the water. For example, the average life of various types of concrete block or keystone in water is approximately a couple of years. A need exists for a retaining wall, which would be resistant to such deterioration.

An additional concern that exists in the construction of retaining walls is the weight of the materials. Concrete blocks, large or medium size stones, timbers or keystones can be heavy and cumbersome to move into the wall location and maneuver when constructing the wall. Many locations for which retaining walls are constructed are positioned in awkward terrain. Heavy building materials are difficult to move into the location and furthermore are difficult to position when constructing the retaining wall thereby adding additional cost and labor for installation. However, the heavy materials are needed once the wall is constructed to provide stability and security to the structure. Therefore, the easy to install light-weight units used for the construction of a retaining wall, which can be weighted once placed into position thus retaining the block in position and stabilizing the completed retaining wall, would be beneficial to construction of such structures.

SUMMARY OF THE INVENTION

The present invention relates to a retaining wall block that is resistant to damage and wear caused by the environment and includes a chamber, which allows the flow of fill material to adjacent blocks below and above. The deterioration resistant block is generally a hollowed frame or shell of a deterioration resistant material that is light-weight and is configured to interlock with adjacent blocks, thereby forming a continuous chamber capable of accepting and retaining any type of filling material. The filling material provides density and stability to the retaining wall block and also ultimately provides stability and security to the retaining wall constructed of such blocks.

Various embodiments of the deterioration resistant block of the present invention comprise a front panel, back panel and two or more side panels, which adjoin the front panel and back panel thereby forming a block having a continuous flow chamber. In various embodiments at least two of the side panels extend from the front panel to the back panel at angles (e.g. less than 90°), thereby allowing for a back panel that is of shorter length than the front panel. The continuous flow chamber of each block generally forms a series of integrated channels which allow the flow of fill material from various blocks when such blocks are positioned in a retaining wall. The blocks of the present invention may further include one or more anchoring devices for securing each block to adjacent blocks or securing them into position in the retaining wall. In various embodiments of the present invention one or more of the panels include one or more aprons for interconnecting the stacked blocks. The aprons assist in positioning and/or adjoining adjacent blocks and facilitating the flow of fill material to the adjacent blocks. Additionally, the aprons assist in retaining the fill material within the adjoined blocks and also may lock the adjacent blocks to each other. As previously suggested, the chambers are adapted for receiving and retaining fill materials, such as sand, dirt, gravel, pea rock, concrete or any other similar material, which provides the permanent weighting and stability of the retaining wall block.

In additional embodiments of the present invention, the blocks may comprise two or more separated panels that are adjoined by a securing mechanism, such as a “T-hook and T-slot”, or a “peg and socket system”. For example, the front panel, side panels and back panel may be separated panels that are secured together to form the blocks of the present invention. These embodiments provide the benefits of providing two or more substantially flat panels and/or nestable panels that may be assembled to form the block. Also, such a process may open other beneficial manufacturing techniques to form such panels, such as extrusion. Such embodiments will also generally provide benefits related to transportation and storage.

Embodiments the deterioration resistant retaining block of the present invention may be used in constructing retaining walls on a number of property terrains, such as along waterfront properties. The deterioration resistant blocks are particularly useful for terrains near water or underwater due to their resistance to degradation. However, the deterioration resistant blocks could also be used for land applications for those that want a light-weight retaining wall block that can be filled on-site to add weight and stability and doesn't require heavy equipment for moving. Therefore, the deterioration resistant retaining wall block could be utilized to construct any form of wall or fence structure.

One unique feature of the present invention is the lightweight characteristic of the block before it is filled. As previously mentioned, embodiments of the present invention can be waterproof and may be filled with any type of fill material located at the site, such as rocks (e.g. crushed rock and pea rock), sand, gravel, soil, concrete or similar materials. The filling characteristic of the deterioration resistant block means that when the block is not filled it is very light-weight. The light-weight feature provides individuals constructing such walls the advantage of easily moving large numbers of the blocks to the site of construction with relative ease. Furthermore, the lightweight characteristic of the blocks allows for easy maneuvering of the blocks into final position when constructing a retaining wall or revetment and still allows for the stability found in heavy blocks after they are filled. These characteristics are met by the block being made of a lightweight material, such as plastic, and by it also being configured to receive a heavy fill material once it has been placed in its final position on the retaining wall.

Individuals would be more inclined to install block made of a deterioration resistant material themselves rather than cement block, timbers, dry cement process block (e.g. Keystone® or Anchor® block) and the like, because of the ease of installation, due to the lightweight material and also the longevity of the block. The weight of most regular retaining wall block is approximately 30–120 lbs, whereas embodiments of the present invention may be approximately 0.1–10 lbs. Of course, weight may vary depending on the size and materials utilized in manufacturing embodiments of the present invention. Also, as previously mentioned the blocks of the present invention achieve stability and weight by filling the block with an appropriate fill material either prior to or after it has been permanently installed.

Embodiments of the present invention further fills an unmet landscaping need for shorelines in that the deterioration resistant blocks are easily manufactured. Examples of possible manufacturing methods include but are not limited to injection-molding, extrusion, roto-molding and blow-molding. Also any high volume application for production may be utilized in manufacturing the present invention. The individual units are light-weight, aesthetically pleasing, easy to install, prevent shoreline and other terrain erosion and compliment existing retaining wall block. Various embodiments of the deterioration resistant blocks of the present invention are also waterproof, can withstand ice damage due to their flexible nature and are easily replaced or repaired in case of damage. Furthermore, they are rugged and require very low maintenance. Additionally, embodiments of the present invention are easily transportable and storable due to their light-weight and possible stacking and/or nesting features.

As previously suggested, embodiments of the present invention are also resistant to deterioration, such as wear, discoloration, crumbling and breaking. Therefore, the deterioration resistant block does not have to be replaced as often and/or increases the lifespan of the retaining wall. Due to these characteristics, the blocks of the present invention generally have a much greater lifespan than the life of a regular dry cast concrete type block or timber. The increased lifespan of the block translates to fewer or no occurrences of replacement of individual blocks or the potential complete reconstruction of the entire wall. Furthermore, retaining wall materials, such as concrete block formed by the dry cast process, (e.g. Keystone® blocks) and timbers are typically not used in water applications because they dissolve, crumble and/or break down over time and exposure. The durability and resistant characteristics of the present invention reduce and prevent this deterioration, therefore making it very beneficial for all applications that come in contact with water.

Another consideration relating to the water application of embodiments of the retaining wall block of the present invention is the block's resistance to ice damage when installed around a body of water when it freezes. When ice expands and/or moves it shifts, tears and damages various types materials utilized for shoreline retention, such as concrete block formed by the dry cast process, rip rap, landscape timbers or anything rigid. Embodiments of the present invention can be manufactured with a material that has flexibility, such as non linear low density polyethylene, that may be designed to flex in a similar way as a Rubbermaid® trash container. Considering that the deterioration resistant block would be filled with a fill material, the deformation would be minimal, but still enough to prevent damage to the retaining wall block and/or the entire wall. Furthermore, upon melting or shifting of the ice the deterioration resistant block would return to its original configuration.

Another advantage of embodiments of the present invention relates to the high cost of waterfront property and people's inclination to improve their property to keep it well-maintained and aesthetically pleasing. As previously mentioned riprap, is commonly stacked along property shorelines to prevent erosion. The trouble with this shoreline preservation application is that the rock leaves many crevices for organic material to reside and, since it is close to water, the crevices are prominent areas for the growth of vegetation. One advantage of embodiments of the present invention is that they are designed to fit next to each other, which reduces the amount of organic material lodging between the blocks, thereby preventing vegetation from growing in such structures.

In addition, many waterfront properties suffer water damage when water levels rise above the shoreline. The retaining wall block of the present invention is a solution to water retention and erosion problems in such areas of threatening high or rising water levels. Furthermore, the retaining wall block poses a solution in locations where there is a flood plane or areas that are washed out by any type of water movement. Sandbags have been a solution to such problems, but are not a permanent or aesthetically pleasing solution. The retaining wall block can replace sand bags in an area for which a more permanent and aesthetically pleasing alternative is desired.

As previously suggested, the deterioration resistant retaining wall block can comprise any type of shape, configuration, color and design. In addition the retaining wall block may include any design or color located anywhere on any panel or wall of the block. Furthermore, the utilization of conventional type materials for retaining walls, such as concrete blocks, timbers or keystones, are heavy to install and do not provide long term or permanent solutions, due to the previously mentioned deterioration problems. Therefore, the present invention provides an aesthetically pleasing solution and replacement for materials, including sandbags, concrete, mortar block, or rip rap, presently utilized in retaining wall construction.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1adepicts one embodiment of the deterioration resistant retaining wall block10comprising a front panel12, a back panel14and one or more side panels16. The side panels16of this embodiment operably join the front panel12and back panel14to form a retaining wall block10having a continuous flow chamber18. The continuous flow chamber18is positioned within the front panel12, back panel14and side panels16.

It is noted that various embodiments of the retaining wall block of the present invention include no top panel or a partial top panel and no bottom panel or a partial bottom panel, thereby providing an open top and bottom to allow for the substantially uninhibited flow and/or commingling of fill material from one block to adjacent blocks above and/or below in the continuous flow chambers when such blocks are operably adjoined or positioned in proximity to each other. In other embodiments, the bottom panel may include one or more apertures to allow for at least a partial alignment of openings, thereby allowing the flow and commingling of fill material from one block to blocks positioned above and/or below.

In an alternate embodiment, as depicted inFIG. 1b,the retaining wall block10may comprise a beveled front that includes one or more bends, slants or creases in the front panel12.FIG. 1bdepicts one embodiment of the retaining wall block of the present invention, wherein the front panel12is beveled thereby taking on a tri-panel appearance. It is noted that the front panel12may also be rounded rather than beveled to provide a more natural appearance. Similar to the embodiment depicted inFIG. 1a,the open top and bottom of each retaining wall block10that includes the beveled front panel12also allows for the receiving of fill material that may flow through the block10and commingle with the fill material in one or more adjacent blocks positioned above and below.

Other embodiments of the present invention, as depicted inFIGS. 2a–2cinclude retaining wall blocks in a panel block design. Similar to the retaining blocks ofFIGS. 1aand1b,the panel blocks of the present invention generally comprise a front panel12, a back panel14and one or more side panels16. However, rather than an integral joining of all panels, the panel blocks20include two or more separated panels that are operably connected with one or more securing mechanisms22to join the two or more panels, thereby forming the block20. In other embodiments the panel blocks20require securing mechanisms22to join three or more panels to form the panel block22. Also, in still other embodiments, the panel block20of the present invention requires securing mechanisms22to join four or more separated panels to form the panel block20. In many of these embodiments, the side panels16are operably joined to the front panel12and back panel14with two or more securing mechanisms22to form a continuous flow chamber18within the panel block20. Similar to the retaining wall blocks10described above, the continuous flow chamber18of the panel block is positioned within the front panel12, back panel14and side panels16.

In other embodiments, the panel block20may also include a front panel12that is beveled (e.g. beveled to take on a tri-panel appearance). It is noted that the front panel12of the panel block20may also be rounded or provided in other shapes rather than beveled as depicted inFIGS. 2aand2b.

As previously mentioned, the panel blocks20generally include one or more securing mechanisms22that provide a sufficient means for securing the separated panels to each other. A sufficient means is generally one wherein the panels will not release when the force of the fill material is applied to the panels12,14,16of the panel block20.FIG. 3adepicts one side panel16that includes part of a securing mechanism22that may be utilized to form a panel block20similar to that depicted inFIG. 2a.It is noted that the panel or variations thereof, depicted inFIG. 3a,could also be utilized as a front panel12or back panel14. The securing mechanism22of some embodiments includes a T-hook positioned at one or more ends of the panel16that fits securely into a T-slot positioned on an adjacent panel12,14, or16. By inserting a T-hook into a T-slot, one corner of a panel block20is thereby formed.

In another embodiment, as depicted inFIG. 3b,the panel16includes a securing mechanism22including a series of threads24that are part of a peg and socket system. It is noted that the panel16depicted inFIG. 3bcould also be utilized as a front panel12or back panel14.FIG. 2bdepicts one embodiment of the panel block20of present invention before the attachment of a front panel (not shown) wherein the side panels16are operably joined to the back panel utilizing a securing mechanism22that is one embodiment of a peg and socket system. In operation the panels12,14and16are positioned so that threads24of each adjacent panel intertwine, thereby forming a slot that a peg or pin26can be inserted to secure the panels12,14,16. An exploded view of the securing mechanism22of this embodiment is depicted inFIG. 2c.In this embodiment, the insertion of the pegs or pins26into the threaded sockets24secures the front panel12, back panel14and the side panels16together in a manner similar to a door hinge. It is noted that other peg and socket systems may be utilized to secure the panels when forming the panel blocks20of the present invention.

FIG. 2ddepicts another embodiment of the panel block20of the present invention wherein the block20includes side panels16and a back panel14that are formed or manufactured in a single part, thereby foregoing the need for one or more securing mechanisms to secure the side panels16with the back panel14. Such an embodiment has benefits in providing for additional stability of the block structure and the ability to manufacture the entire block20in a limited number of parts (e.g. two part system; a side/back panel and a front panel). Such embodiments allow for the side and back panels14,16to be formed in a single part by processes that have manufacturing benefits, such as extrusion or thermoforming. Once the single side/back panel14,16is provided, it may be adjoined to a molded and/or fabricated front panel12by securing the pieces together with one or more securing mechanisms22.

In yet another embodiment of the present invention a securing mechanism22may be provided as a hybrid of the T-hook and T-slot system and the peg and socket system. In such embodiments a peg26including a plurality of panel slots28, as depicted inFIG. 4a,may be positioned to receive and secure two or more panels to form one or more corners of a panel block20. Examples of some peg and panel systems are depicted inFIG. 4b–4d.

In still another panel block embodiment, the panels may include two or more slits to accommodate the securing of various panels together.FIG. 3cdepicts a side panel16of the present invention that includes a pair of slits30, one opening upward and one opening downward. It is noted that the embodiment depicted inFIG. 3cand variations thereof could also be utilized as a front panel12and/or back panel14. In operation the slit30of a panel with a downward opening slit is inserted into the slit30of a panel having an upward opening slit. The nesting of the slits of the two panels forms a corner of one embodiment of the panel block20of the present invention. The remaining panels may then be joined in a similar fashion or with an alternative securing mechanism (not shown) to form the continuous chamber and a panel block embodiment.

FIGS. 2band2dalso depict embodiments of a panel block20of the present invention that include a stabilizing partition32. The stabilizing partition may be included in the retaining wall block10or panel block20to further stabilize the block structure, take pressure off of the front panel caused by the packed fill material and also provide a divider so that different fill materials may be added to the same block10,20(e.g. a packing material toward the back of the block and a planting fill material in the front of the block). In various embodiments the stabilizing partition32may take a form similar to a side panel or back panel that includes attachment members34(e.g. T-hooks, pegs . . . ) positioned on the ends to act as part of the securing mechanisms22. In some embodiments the partition32may include peg extensions36that operate as a block positioning and securing means when constructing a retaining wall. The peg extensions36may be placed anywhere on the partition including the ends and/or dispersed along the bottom edge of the partition32. In construction of a wall, the peg extensions36may butt up against one or more partitions present in blocks positioned below, thereby holding the block20in position and providing an indication of proper positioning of the block20. It is noted that the peg extensions36may be included on the back panel16rather than or in addition to the partition32so as to butt up against the back panel of the blocks positioned below. Such peg extensions may be utilized in integral blocks10(blocks with no securing mechanisms) or panel blocks20.

In the blocks of the present invention, including the panel blocks20, the front panel12will generally include a molded and/or fabricated texture and/or pattern in the deterioration resistant material that is visible to an observer. In various embodiments of the present invention the exposed surface of the front panel12will have a natural earthen appearance simulating the texture and color of natural earthen surfaces. For example, the exposed surface of the front panel12may be textured and colored to have the appearance of rock, stone, sand, soil, clay, wood, trees and foliage, water, or any other natural earthen appearance. Additionally, in other embodiments, the exposed surface of the front panel12may further include one or more designs (e.g. symbols, company names, logos, images) that may be positioned in the natural earthen appearance texture and color (e.g. a company logo embedded in a stone color and texture). Also, in other embodiments of the present invention, the front panel12, as depicted in theFIG. 5, may further include a design, such as the appearance of multiple bricks, stones, or blocks. This allows for the installation of larger blocks in a wall that appears to include a multitude of bricks, stones or blocks.

As previously indicated the blocks10,20of the present invention generally include one or more side panels14that engage and extend from the front panel12back to engage with a back panel16. As depicted generally inFIGS. 1a,1band2a–2c,in some embodiments of the present invention, the side panels14engage the front panel12at angles to provide for a tapering of the block as it moves back in width. The angle38formed between the front panel12and side panel14is generally less that 90° when the front panel12is substantially straight and less than 150° when the front panel12is rounded or beveled. In other embodiments, the angle38is between about 45° and 85° for substantially straight front panels12and between 60° and 120° for beveled and rounded front panels12. In various embodiments the side panels14may extend from the front panel12at angles that would allow them to engage each other at the back of the block, thereby forming the back panel16and chamber18by their engagement (e.g. a triangle or diamond configuration). Finally, in various embodiments, the top edge of the side panels14may slightly slope down from front to back, thereby providing a back end of the block that is slightly lower than the front of the block (e.g. 0.5–10 mm).

In other embodiments, as illustrated inFIGS. 6aand6b,the retaining wall block10further includes an optional partial top panel40that is exposed when a retaining wall is constructed. The partial top panel40assists to close or partially close the top front portion of the block10,20that may be exposed to the outer environment. In the embodiment depicted inFIG. 6b,the top panel40further includes a protrusion42, which is intended to fill the void created by the beveled front panel12when constructing a retaining wall that includes staggered rows of such blocks10. SeeFIGS. 7aand7bfor a depiction of a perspective view of a retaining wall44including staggered rows. In various embodiments, the blocks10,20include a partial top panel40that extends from the front panel12back to no more than 75% of the width of the block. It is noted that block width is measured from the front panel12to the back panel14of the block. In other embodiments of the present invention, such a partial top panel extends from the front panel no more than 50% of the width of the block. In yet other embodiments the partial top panel20extends from the front panel no more than 35% of the width of the block. Such a partial top panel40provides for at least a partial sealing of the block at the top front portion, of which may be exposed when the retaining wall is constructed in a configuration wherein the wall inclines back toward the surface or slope intended to be protected. It is noted that in various embodiments the top panel40may further include one or more planting apertures46that may allow plant growth from the top surface of the block. As previously suggested, the open top and bottom of each retaining wall block10,20allows for the receiving and commingling of fill material that may flow from and through the block10,20to one or more adjacent blocks10,20below.

A partial top panel40may also be incorporated into embodiments of the front panel12utilized in embodiments of the panel blocks20of the present invention.FIG. 8adepicts a front panel12of a panel block20wherein the partial top panel40extends back from the front edge of the panel block20. The partial top panel40of this embodiment further includes optional top side panels48that extend downward from the partial top panel40and may extend over or within the side panels16of the panel block (not shown). The partial top panel40ofFIG. 8afurther includes one or more cover tabs50to assist in securing the top panel40into the fill material or over a partition (not shown). The partial top panel40may also include one or more planting apertures46, as depicted inFIG. 8b,that allows for the growth of plants from the top of the panel blocks20. Also, various embodiments may also include more than two securing mechanisms22as depicted inFIG. 8a.This is advantageous if partial blocks are required, as will be explained further below. By providing additional securing mechanisms22, the cutting of the front panel12still allows for the remaining portion of the front panel12to have two outer securing mechanisms22for securing a side panel to the cut front panel. Partial blocks may further include one or more shorter stabilizing partitions (not shown) to assist in securing the two halves of the block together after cutting and provide addition stability to the partial block.

FIGS. 9aand9bdepict a front perspective view of two embodiments of the present invention wherein the retaining wall block10of the present invention further includes one or more anchoring devices for securing each block to adjacent blocks or securing them into position in the retaining wall. Generally the anchoring devices may be adjoined, rested within or inserted into the top panel12, back panel14and/or side panels16. For example, as depicted inFIGS. 9aand9bthe anchoring devices include one or more securing aprons52adjoined to the front panel12, side panels14and/or back panels for interconnecting the stacked blocks10and assisting the flow of fill material within the continuous chambers18of the blocks. As depicted inFIGS. 9aand9b,the aprons52may include a plurality of teeth54that extend downward from one or more of the various panels12,14,16into the adjacent blocks10below, thereby adjoining the blocks10and formulating the continuous chamber system. The aprons52generally secure the block into place and inhibit leakage of the fill material when it is poured into and retained within the chambers18. The teeth54of the present invention allow for indentations between the teeth54that may accommodate the side panels16of adjacent blocks10below. The indentations further provide for a secure and flush fit of the adjoining blocks10. Also, it is noted that individual teeth may be removed or cut away to further assist the proper fit of blocks in the wall.

In another embodiment of the present invention, as depicted inFIG. 9c,the aprons52include one or more slots56configured to accept one or more interlocking members58, which are positioned on the top panel400. The interlocking members58extend inwardly from the edge of the top panel40a length sufficient to pass through the slots56of the adjacent blocks10positioned above.

In an alternate embodiment of the present invention the apron52adjoined to the front panel12may extend forward. SeeFIGS. 10a–c.The extension of the apron52forward allows for a secure locking of adjacent blocks by inserting the forward extending apron52under the top ledge40of the adjacent blocks10below.FIG. 10bdepicts the apron52offset from the front panel12of the block10. In such embodiments, the apron52would be secured to a bottom panel (not shown). The bottom panel may be secured to the front panel12and side panels16or hingedly attached to the front panel12. Such an offset apron52allows for the bottom panel to partially extend over the top panel40, thereby further assisting in sealing the continuous chamber from the environment in front of the wall.

In one embodiment of the present invention, as depicted inFIGS. 10aand10b,an apron52may attached to an extension60of the back panel14. The extension60may be adjoined to and extend along the back panel14in a manner that would allow it to rotate or swing inward, thereby allowing the apron52to engage the back panel14of the adjacent blocks10below. The extension60may be adjoined to the back panel14by any means known in the art, such as hinges (e.g. living hinge), hooks, flexible plastic portions, perforations or any other means that would allow the extension60to swing inward.

In an alternate embodiment depicted inFIG. 10cthe back panel14includes one or more hooking devices62. The hooking devices62are adjoined to the back panel14similar to the extensions60ofFIGS. 10aand10b.Generally, the hooking devices62are capable of swinging inward and engaging the back panels14of adjacent blocks10below. One or more apertures (not shown) may be positioned on the top portion of the back panel14to accept the hooking device62and thereby lock the blocks10,20in place. Examples of hooking devices include but are not limited to latch hooks, clips, snaps and the like.

The back panel14may also include or be adjoined to a flange64.FIG. 10ddepicts the side view of an embodiment of the present invention, which includes a retaining flange64adjoined to the back panel14of the block10,20. On a constructed wall, each retaining flange64is a wall retention device that operates to inhibit outward movement of the wall. Normally, the retaining flange64extends downward from the back of the back panel14and rests against the back of the retaining block10,20located below. The retaining flange64may be a unitary piece extending downward from the back of the retaining block10,20or a series of fingers (not shown) extending downward from the back of the retaining block10. Optionally, a clipping member66may be included in proximal location to the flange64, thereby forming a clip that can accept and retain the upper portion of the back panel14of the blocks10,20below.

FIGS. 11a–11band12a–12bdepict various embodiments of top covers68and bottom covers70, which are configured and adapted to securely fit over or under embodiments of the retaining wall blocks10of the present invention. Generally, in some embodiments, the top covers68and bottom covers70utilized in constructing some of the retaining walls of the present invention are at the very top of the wall and very bottom of the wall to at least partially seal the continuous chamber channels. However, the use of such covers68,70at intermediate locations through the wall may also be performed. In various embodiments of the present invention, the top cover68generally includes a continuous top panel72that includes overlapping edges74, which overlap securely over the outside side and back panels14,16. In some embodiments of the invention, the overlapping edges74may be present around the entire perimeter of the top panel72. Alternately, a forward extending apron52may be positioned at the front of the top cover68and utilized to secure the cover68to the adjacent blocks10,20below by inserting the apron52under the top panel40of said blocks10,20.

Embodiments of the bottom covers70of the present invention, as depicted inFIGS. 12aand12b,may include a bottom panel76with attached bottom side walls78extending around the perimeter of the bottom panel76. The side walls78may be configured to overlap the front, back and side panels (depicted inFIG. 12a) or configured to nest within the front, back and side panels12,14and16(depicted inFIG. 12b). In other embodiments, as depicted inFIG. 12a,the overlapping sides may include an optional channel80for receiving and retaining the front, side and back panels12,14, and16of the adjacent block10,20above. Finally, the front of the bottom cover70may include one or more apron apertures82opening to the side or bottom of the bottom cover70for receipt of an apron52from the adjacent block10,20above. Alternatively, the top covers68and/or bottom covers70may include only a top panel72or bottom panel76that nest and optionally secure into place just within the front panel12, back panel14and side panels14of the block10,20. Additionally, the top cover68may include one or more planting apertures46for allowing the growth of vegetation from the block. An illustration of one such embodiment is depicted inFIG. 13.

Another embodiment of the present invention is depicted inFIG. 14. The embodiment shown inFIG. 14comprises a deterioration resistant retaining block10,20wherein more than one chamber18is included within the retaining block10,20. The multiple chambers18are defined by interior partitions32that may extend either the length and/or the width of the block10,20. The interior partitions32may also be utilized to add additional support to the retaining block10,32to prevent any possible crushing or expansion of the block10,20. The interior partitions32are within the interior of the retaining block10,20and are present to define separate chambers that can accommodate filling of each individual chamber18with appropriate fill material, such as sand, gravel, crushed rock, pea rock, soil, cement, concrete or any other suitable material.

Multiple chambers18also allow for the retaining block10,20to be cut into various shapes or into partial blocks and still maintain a chamber18that can receive and retain fill materials as illustrated inFIG. 14a.FIG. 14adepicts a section of the retaining block10,20as shown inFIG. 14wherein the block10has been cut in half. The ability to cut the retaining block10,20and still retain the same features is particularly useful in preparing ends and awkward segments of retaining walls. In one embodiment, a block20, as depicted inFIG. 2b,and a front panel12, as depicted inFIG. 8a,may be cut to a desired width, and adjoined with a side panel to secure the front panel12to the back panel14of the block20utilizing an interior securing mechanisms22positioned on the front panel12and back panel14.

In another embodiment, as depicted inFIG. 15a partial block may be formed by cutting a retaining wall block10,20and nesting the first front section84of the front panel12within the second front section86of the front panel12and nesting the second back section88within the first back section90. The nested partial block sections may be adjoined using any attachment means known in the art; for example clips, tacks, rivets, adhesives, securing mechanisms as described above, or combinations thereof. It is noted that the first front section84and either or both back sections88,90may be trimmed to properly fit when nesting. Alternate top and bottom covers (not shown) configured to conform to the various shapes of a divided retaining block10,20may also be provided or formed by cutting. As previously mentioned, partial blocks may further include one or more shorter stabilizing partitions (not shown) to assist in securing the two halves of the block together after cutting and provide addition stability to the partial block.

FIG. 16illustrates a top view of a retaining wall block wherein multiple units92are incorporated into a single block94. A single multi-unit block94provides the appearance of multiple retaining blocks present in a single structure and generally includes a front panel12, back panel14and two or more side panels16operably adjoined to form two or more chambers18. A top cover (not shown) or bottom cover (not shown) may be provided for a multi-unit block94and may include a single sheet or multiple sheets of material which covers each unit92. The interior of the retaining block94of this embodiment includes one or more interior partitions32.FIG. 16adepicts the front view of the multi-unit retaining block61, which has the appearance of multiple separate units92. In various embodiments, the multiple multi-unit blocks94provide the appearance similar to the partial assembly of a retaining wall comprising a plurality of individual blocks, such as depicted inFIG. 17. The multi-unit retaining block94may be a unitary structure or may include multiple components, such as a multi-unit block94including individual top or bottom covers (not shown).

Also, as depicted inFIG. 16, the multi-unit retaining wall block94may have disengaging tabs96positioned between each individual unit92on the front and back of the multi-unit block94for disconnecting units92of the block94. One example of the tabs96may be one or more thin sections of flexible or rigid plastic positioned between the units92that adjoin and separate each individual unit92. The units92can be separated or pushed together in the back to curve a wall by simply cutting or removing the tab96.

In an alternate embodiment of the present invention, the multi-unit block94may include a plurality of panels, similar to those previously described in the explanation of the panel block20embodiments.FIG. 18depicts another embodiment of the multi-unit block of the present invention, wherein a plurality of front panels12, back panels14and side panels have been adjoined with securing mechanisms22to form a multi-unit block94.

FIGS. 19–23depict other embodiments of the present invention wherein the block10or panel block20include an interconnecting device98. It is noted that in the panel block20embodiments, the interconnecting device98may be a securing mechanism as described above or a variation thereof. In various embodiments, as depicted inFIG. 20the interconnecting device98includes a peg and socket system having one or more insertable pegs26to adjoin two or more blocks by inserting the pegs26into threads24that form a socket. The sockets are generally positioned on an edge or just inside the edge of the front, side and/or back panels12,16,14. The sockets may be integral to the front or back panels12,14or may be secured to the panels12,16,14in any manner known in the art. The pegs26are configured to be securely receivable in the sockets and may be configured to swivel the block10,20. The insertable pegs26can be made of any shape and size, which can be securely fit into the sockets.

Another type of anchoring device included in the present invention may be a side locking mechanism. As depicted inFIG. 21, one or more interlocking spools100, each comprising an elongated member102operably adjoined to one or more flat cylinder104attached to one or more ends, may adjoin adjacent side blocks10. Each cylindrical end104of each spool100may be inserted into connecting apertures106positioned on the side panels16of adjacent blocks10,20thereby securing them together.

Alternatively, in one embodiment of the present invention side by side adjacent blocks10,20may be adjoined with a clipping device108. In one embodiment the clipping device108my be configured in a U shape and sized to snuggly fit over the side panels16of two adjacent blocks. An illustration of one embodiment of a clipping device is depicted inFIG. 22.

FIG. 23depicts an additional embodiment of the present invention, similar to hook attachments, wherein the retaining wall block10or panel block20includes an interlocking feature that comprises a hook or peg110. An optional pocket (not shown) may also be placed in the block10for receiving the hook110from adjacent blocks10. In such an embodiment one or more hooks or pegs110extend from one side panel16of a retaining wall block10,20and may be inserted over the opposite side panel16of an adjacent block10,20. Such interlocking mechanisms provides for a overall secure retaining wall structure by reducing the amount of movement that may occur during filling with unsecured individual blocks.

Another advantage of certain embodiments of the blocks of the present invention is that they also allow for easy storage and transport due to the stackable capabilities present.FIG. 24adepicts a plurality of such blocks10in a stacked arrangement. For example, an individual block10may be inserted into chamber18of another block10, thereby creating a stackable arrangement.

In other embodiments of the present invention, panel blocks are easily transported and stored by separating the front panel12, back panels14and side panels16and stacking and/or nesting the respective panels12,14,16when in transport or storage.FIG. 24bdepicts a plurality of panel blocks20, as depicted inFIG. 2b,in a nested position.

The blocks10of the present invention may also be utilized with other wall stabilizing products to secure and stabilize a structure constructed of such blocks10. For example,FIG. 25depicts an embodiment of a retaining wall block10wherein a structural grid112is attached to block10or panel block20(e.g. attachment to the upper back panel14, bottom panel (not shown or peg extensions36on the back panel14or partition32). The grid112is buried behind the wall constructed of the blocks of the present invention and acts to support and stabilize the wall from moving forward away from the embankment it is protecting.FIG. 25bdepicts an additional embodiment of the grid112positioned between the rows of a retaining wall that includes the block10,20,94of the present invention having a textured front panel12and a molded or fabricated design.

As previously mentioned, the present invention may be manufactured from a deterioration resistant, substantially rigid composite or polymeric material including, but not limited to, plastic, a rubber composition, fiberglass, or any other similar material or a combination thereof. Preferable materials comprise light-weight and slightly flexible polymers, such as high and low density polyethylene. However, other plastics may also be used. Examples of other plastics include, but are not limited to polypropylene, acrylonitrile-butadiene-styrene (ABS), poly(butylene terephthalate) (PBT), poly(cyclohexanedimethylene terephthalate) (PCT), styrene-acrylonitrile copolymers (SAN), polystyrene, polycarbonate and combinations thereof. It is also noted plastics the include filler materials, such as saw dust or paper byproducts may also be used in the present invention. Generally, the embodiments of the present invention may comprise any type of material that would have the similar characteristics to plastic, vinyl, silicone, fiberglass, rubber or a combination of these materials. It is noted that the material utilized in the present invention should be rigid enough to hold its form upon addition of filling material and also when placed in contact with other objects. Also the panels of the blocks should be substantially non-collapsible when in a filled and stacked state. Another preferable material may be comprised of a material similar to that utilized in the production of some types of garbage cans or the utilization of recycled rubber from objects such as tires. Such materials would be capable of holding rigidity and still offer flexibility when placed in contact with other objects, such as ice. Also, such materials have the ability to regain its original form when the object or material has been removed.

Embodiments of the present invention may also vary in appearance. Since embodiments of the present invention may be manufactured by a process such as injection molding, extrusion, thermo-forming, compression molding, roto-molding and the like, the molds may include any type of design or shape. Furthermore, the front panels of the retaining wall block10or20could be molded in almost any type of configuration. In one embodiment, multiple retaining wall blocks could be molded to include designs that, when positioned on a retaining wall, would complete a larger single design, such as the spelling of a company or school name in large letters or the completion of a large image. Also, since the present invention may be manufactured from a number of different products, such as plastic, a rubber composition or fiberglass, the retaining wall block may comprise any color or a multitude of colors. For example, a retaining wall installed in a beach setting may be manufactured of a plastic or rubber product and be colored in so that organic matter wash up on it would not show up as readily or may take on the appearance of sand.

As previously suggested the environment resistant retaining wall block is utilized in the construction of any type of wall or border. In application, the blocks10or panel blocks20are provided in a usable form. For the blocks10no additional preparation may be required. However, for the panel blocks20, some assembly may be required. Next, a foundation is created in the area that the wall or border is to be constructed. The foundation preferably is flat and or level and can accommodate one or more retaining blocks10. In various embodiments one or more courses of block10,20may be partially submerged or totally submerged below the earth surface to provide wall stability. Once a foundation is completed, a first row is laid by positioning the blocks10,20,94in their proper position side by side and filling each retaining block1020,94with a fill material while back filling behind the block until the row is completed. A fill material packing device may be utilized while filling to ensure stability of the fill material as the wall is constructed. The chamber18is normally filled with materials such as sand, crushed rock, pea rock, gravel, dirt, cement, concrete or other like materials to provide weight and structure stability to the retaining wall block10and the entire retaining wall. The filling of the retaining wall block10gives it the added weight that it needs to retain its structure and hold it in place. A funneling device may be utilized, which fits securely into the openings or apertures of the retaining wall block to guide fill into the chamber of the block. The first row and subsequent rows may be straight or rounded. Upon completion of the first row, additional rows are constructed by placing the retaining wall block10in the proper position and performing the same filling and back filling process until a continuous retaining wall is completed. It is noted that with the continuous chamber of the present invention, multiple rows can be secured in place before filling. However, it is recommended that filling be done regularly (e.g. row by row) to ensure proper packing of the fill material. Generally, a continuous retaining wall includes stacked rows wherein individual retaining blocks are placed adjacently to one another thereby eliminating or minimizing cracks or gaps in the wall. Rows of retaining wall blocks10may be positioned directly over other rows of retaining wall blocks10wherein the blocks are positioned directly over other blocks. However, many embodiments of the present invention provide a constructed wall wherein the blocks are staggered in alternating rows. SeeFIGS. 7aand7bfor an illustration of a staggered retaining wall. It is noted that each retaining wall block10,20,94placed in the retaining wall is configured to retain and seal the contents of the fill material back towards the slope when the wall has been properly constructed. This may be further accomplished by applying top covers42and/or bottom covers44that at least partially seal the continuous chamber or by plant vegetation on the top row of the retaining wall. Furthermore, the retaining wall blocks10,20,94of the upper rows may be further sealed into place by an overlap of the back of retaining wall blocks10,20,94of lower rows if a retaining flange64or peg extensions36are included on the block. In the alternative or additionally, each individual retaining block10may be locked into position with adjacent blocks if spools100and apertures106, clipping devices108or hooks110are present with the retaining block10,20,94.

Upon completion of the top row of the retaining wall, a cover or capping block114may be placed over the top row to close and seal the continuous chamber of the retaining wall and to provide a finishing border to the top of the retaining wall. One embodiment of a capping block114, as depicted inFIG. 26, may be polygonal in shape and include textured and designed faces on both the front panels12and back panels16of the block114. The capping blocks114may further include pegs (not shown), similar to those depicted in the previous block embodiments, that may be utilized to secure the capping block to the blocks positioned below. Alternatively, the capping blocks may be secured to the blocks10,20,94below by any means known in the art, such as clips, tacks, adhesives or the like. The capping blocks114may be filled with a fill material, similar to the other embodiments of the present invention, or may be a simple thinner block that may include a plurality of reinforcing partitions116as disclosed inFIG. 26.

Embodiments of the present invention may also be used in conjunction with regular dry cement process blocks, bricks or stones, such as those produced by Keystone® or Anchor® Wall Systems. A retaining wall constructed in water or along a waterfront property may utilize the retaining wall block of the present invention at water level and below and then the regular keystone or retaining wall materials can be used on top of the retaining wall block of the present invention. The utilization of the retaining wall block of the present invention would be easy to match colors with the conventional retaining wall building materials because the materials utilized to manufacture the present invention can be colored and designed to match virtually any type of retaining wall construction material.

Furthermore, the retaining wall block may be manufactured in a multitude of different sizes, shapes and configurations. For example, an embankment or steep shoreline could support a retaining wall configured in a step like arrangement or design. Such a structure, may be utilized as a retaining wall and/or a stairway down to the beach or to the water.

While the invention has been illustrated and described in detail in the drawings and foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.