Abstract:
Single masonry units mate with like units to build straight walls, inside curves, outside curves and most any angle corners and maintains finish on all exposed surfaces. The interlocking fastening system provides simple construction and automatic wall alignment.

Description:
RELATED APPLICATIONS  
       [0001]     This application claims the benefit of provisional U.S. Patent Application Ser. No. 60/500,492, filed Sep. 5, 2003, and entitled “Interlocking Masonry Wall Block.” 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates to a masonry block for stacking on other like-shaped blocks in a staggered, interlocking and offset manner to form a wall that is particularly well-suited for use as a vertical seating wall around patios, pool decks, walkways, and the like.  
       BACKGROUND OF THE INVENTION  
       [0003]     A variety of masonry block designs have been developed for building vertical seating walls. Wall block designs require a mechanism for securing the blocks together to produce a stable wall structure. Conventional interlocking masonry wall blocks are heavy and difficult to handle. In addition, several different block shapes must be combined to form the straight and curved sections of a serpentine wall. The need remains for masonry wall blocks that are cost-efficient to manufacture and easily assembled into a stabile and durable wall.  
       SUMMARY OF THE INVENTION  
       [0004]     Each block in an upper course of blocks is laid in a staggered manner relative to a lower course so that the upper block is placed atop two lower blocks. Single block units mate with like units to build straight walls, inside curves, outside curves and angle corners. Laterally adjacent blocks may be similarly aligned. Alternatively, laterally adjacent blocks may be inversely aligned so that the front wall of one block lies adjacent the rear wall of the adjacent block.  
         [0005]     According to one aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The core has a width less than 1.25× the width of the projections. The projections are adapted for placement within the core of an underlying block in the retaining wall.  
         [0006]     In one embodiment, the core is offset between the front and rear wall outer surfaces. In another embodiment, the core is centered between the front and rear wall outer surfaces.  
         [0007]     In one embodiment, the first and second projections are offset between the front and rear wall inside surfaces. In another embodiment, the first and second projections are spaced equidistant between the front and rear wall inside surfaces.  
         [0008]     According to another aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The projections are adapted for placement within the cavity of an underlying block in the retaining wall. At least one of the first and second side walls includes a score line between the cavity and the respective first or second projection that extends from the front wall outer surface to the rear wall outer surface.  
         [0009]     In one embodiment, the core is offset between the front and rear wall outer surfaces. In another embodiment, the core is centered between the front and rear wall outer surfaces.  
         [0010]     In one embodiment, the first and second projections are offset between the front and rear wall inside surfaces. In another embodiment, the first and second projections are spaced equidistant between the front and rear wall inside surfaces.  
         [0011]     According another aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The projections are spaced equidistant between the front and rear wall inside surfaces and adapted for placement within the cavity of an underlying block in the retaining wall so as to provide essentially no setback dimension between the block and the underlying block.  
         [0012]     In one embodiment, there is essentially no setback dimension when the first and second projections are placed within the cavity of the underlying block in an abutting relation to the front wall inside surface of the underlying block.  
         [0013]     In another embodiment, there is essentially no setback dimension when the first and second projections are placed within the cavity of the underlying block in an abutting relation to the rear wall inside surface of the underlying block.  
         [0014]     In one embodiment, the core is offset between the front and rear wall outer surfaces. In another embodiment, the core is centered between the front and rear wall outer surfaces.  
         [0015]     In one embodiment, the first and second projections are spaced equidistant between the front and rear wall outside surfaces.  
         [0016]     According to another aspect of the invention, a masonry wall block for forming a retaining wall comprises a body having a front wall, a rear wall, and first and second side walls that extend from the front wall to the rear wall. The front wall has a length greater than the length of the rear wall such that the first and second side walls converge toward one another as they extend from the front wall toward the rear wall. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The first and second projections are adapted for placement within the cavity of an underlying block in the retaining wall. The front wall of the block is configured to lie adjacent the rear wall of a laterally adjacent block in the retaining wall such that the cavity of the block is positioned to receive the first projection of an overlying block in the retaining wall in an abutting relation to the inside surface of the front wall of the bock and the cavity of the laterally adjacent block is positioned to receive the second projection of the same overlying block in the retaining wall in an abutting relation to the inside surface of the rear wall of the laterally adjacent block.  
         [0017]     In one embodiment, the front wall and the rear wall are of equal width.  
         [0018]     A masonry wall block for forming a retaining wall comprising a body having a front wall, a rear wall, and first and second side walls that extend from the front wall to the rear wall. The front wall has a length greater than the length of the rear wall such that the first and second side walls converge toward one another as they extend from the front wall toward the rear wall. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The first and second projections are adapted for placement within the cavity of an underlying block in the retaining wall. The front wall of the block is configured to lie adjacent the rear wall of a laterally adjacent block in the retaining wall such that the cavity of the block is positioned to receive the first projection of an overlying block in the retaining wall in an abutting relation to the inside surface of the rear wall of the bock and the cavity of the laterally adjacent block is positioned to receive the second projection of the same overlying block in the retaining wall in an abutting relation to the inside surface of the front wall of the laterally adjacent block.  
         [0019]     In one embodiment, the front wall and the rear wall are of equal width.  
         [0020]     According to yet another aspect of the invention, a retaining wall comprises a lower tier of individual blocks, each block having a cavity, and an upper tier of individual blocks. Each block in the upper tier comprises a body having a front wall, a rear wall, and first and second side walls. Each of the walls has inside and outside surfaces and upper and lower surfaces. The inside surfaces of the walls form an open core having a width. The upper surfaces of the walls form an upper surface of the body. The lower surfaces of the walls form a lower surface of the body. A first projection extends from the lower surface of the first side wall and a second projection extends from the lower surface of the second side wall. The projections are spaced equidistant between the front and rear wall inside surfaces and adapted for placement within the cavity of an underlying block in the retaining wall so as to provide essentially no setback dimension between the block and the underlying block. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]      FIG. 1  is a bottom perspective view of a masonry block unit.  
         [0022]      FIG. 2  is a top perspective view of the block shown in  FIG. 1 .  
         [0023]      FIG. 3  is a bottom plan view of the block shown in  FIG. 1 .  
         [0024]      FIG. 4  is a top plan view of the block shown in  FIG. 1 .  
         [0025]      FIG. 5  is a front plan view of the block shown in  FIG. 1 .  
         [0026]      FIG. 6  is a side view of the block shown in  FIG. 1 .  
         [0027]      FIG. 7  is a perspective view of a masonry seating wall formed from like-shaped blocks.  
         [0028]      FIG. 8  is a top plan view illustrating a series of laterally-adjacent blocks inversely aligned to form a straight wall.  
         [0029]      FIG. 9  is a top plan view illustrating the arrangement of a series of inversely-aligned laterally-adjacent blocks to form an angular wall.  
         [0030]      FIG. 10  is a top plan view illustrating an alternative arrangement of a series of inversely-aligned laterally-adjacent blocks to form an angular wall.  
         [0031]      FIG. 11  is a top plan view illustrating an angular wall constructed by alternating courses arranged as in  FIG. 9  with courses arranged as in  FIG. 10 .  
         [0032]      FIG. 12  is a top plan view illustrating the arrangement of a series of similarly aligned laterally-adjacent blocks to form a straight or linear wall.  
         [0033]      FIG. 13  is a top plan view illustrating the arrangement of a series of similarly aligned laterally-adjacent blocks to form a curved wall.  
         [0034]      FIG. 14  is a top plan view illustrating the arrangement of a series of similarly aligned laterally-adjacent blocks to form a wall having straight portions and curved portions.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0035]     An individual masonry block  10  for use in constructing vertical seating walls around patios, pool decks, walkways, etc. is shown in  FIGS. 1-6 . The block  10  has a main body  12  having a front wall  14  having an outside surface  16  and an inside surface  18 , a rear wall  20  having an outside surface  22  and an inside surface  24 , and first and second side walls  26  each having an outside surface  28  and an inside surface  30 . The inside surfaces  18 / 24 / 30  of the walls  14 / 20 / 26  define an open core  32 .  
         [0036]     The upper surfaces of walls  14 ,  20 , and  26  define an upper surface  34  of the body  12 . The lower surfaces of walls  14 ,  20 , and  26  define a lower surface  36  of the body  12 . The upper and lower surfaces  34  and  36  are generally parallel to each other. When laid in place on a horizontal supporting surface, the upper and lower surfaces  34  and  36  are horizontal as well.  
         [0037]     The front wall  14  has a length L F  and the rear wall  20  has a length L R . Each side wall  26  converges toward the other at an angle A as it extends toward the rear wall  20  such that L F &gt;L R , thereby providing the block  10  a generally trapezoidal shape. The front and rear walls  14  and  20  are generally parallel (i.e., both walls  14  and  20  are of an essentially straight or linear configuration), and generally perpendicular to upper and lower surfaces  34  and  36 . It is contemplated, however, that either or both of front and rear walls  14  and  20  may be of a curvilinear configuration, e.g., convex, arcuate, or serpentine configuration (not shown). Front and rear walls  14  and  20  are desirably both finished (split, soft split or textured). The block  10  has a width W B .  
         [0038]     Desirably, at least one score line  38  is provided. In a preferred embodiment, a pair of opposing score lines  38  are provided. In the illustrated embodiment, the score lines  38  take the form of a V-shaped grooves G. The score lines  38  are generally parallel and extend from the front wall  14  to the rear wall  20 . A block  10  may be split along a score line  38  to form an end block  40  presenting a flat end surface  42 , as will be explained in detail later (see  FIGS. 9-11 ).  
         [0039]     Two opposing integral lug projections  44  extend from the lower surface  36  of the block  10 . In the illustrated and preferred embodiment, a first projection  44  extends from the lower surface  36  of the first side wall  26  and the second projection  44  extends from the lower surface  36  of the second side wall  26 . Each projection  44  is desirably positioned between the score line  38  and the outside surface  28  of the respective side wall  26 . The projections  44  are generally rounded or convex, having a radius R L , a height H L , and a width W L . It is contemplated that the projections  44  may take on a variety of other configurations, e.g., rectangular or square, to accommodate specific needs. In a preferred embodiment, each lug projection  44  is generally centered equidistant between the front wall inside surface  18  and the rear wall inside surface  24  such that distance D1 and distance D2 are essentially equal.  
         [0040]     The open interior or core  32  extends completely through the block  10  from the upper surface  34  to the lower surface  36 . The open core  32  does not present a trapezoidal shape as does the block body  12 , but instead has a generally elongated, rounded shape having a length L C , width W C  and radius R C . Desirably, the width of the core  32  is only slightly larger than the width of the projection  44 , such that W C  is only slightly greater than W L . This arrangement allows for easy placement of the projections  44  within the core  32  of an adjacent-tiered block  10  and provides a tolerance allowing for expansion, contraction, or settling movement of the blocks  10 . This arrangement also provides sufficient tolerance for orientating the blocks  10  in various configurations, e.g., curved walls, as will be described later. In addition, this arrangement permits minimal forward or reverse movement of the blocks  10  within the retaining wall, thus providing additional stability to the wall. For example, the core  32  may have a width W C  that is less than twice the width of the projections W L  (W C &lt;2×W L ), and preferably W C  is less than 1.25 times W L  (W C =1.25×W L ). In a preferred embodiment, the core  32  has a width of 1½ inches and each lug projection  44  has a width of 1⅜ inch.  
         [0041]     With reference to  FIG. 3 , the core  32  is desirably slightly offset between the front and rear walls  14  and  20 . For example, in one embodiment, the rear wall  20  is of a slightly greater width than the width of the front wall  14  such that distance D3&gt;distance D4. In this arrangement, there is no or zero setback when the projections  44  are placed in an abutting relation with the inside surface  24  of the rear wall  20  within the core  32  of a similarly-aligned adjacent-tiered block  10 . In an alternative embodiment, the front wall  14  is of a slightly greater width than the width of the rear wall  20  such that distance D4&gt;distance D3. In this embodiment, there is no or zero setback when the projections  44  are placed in an abutting relation with the inside surface  18  of the front wall  14  within the core  32  of a similarly-aligned adjacent-tiered block.  
         [0042]     In an alternative embodiment, the core  32  is not offset, i.e., the front and rear walls  14  and  20  are of equal width, such that D3=D4. In this embodiment, there is no or zero setback when the projections  44  are placed equidistant between the front and rear inside wall surfaces  18  and  24  within the core  32  of a similarly-aligned adjacent-tiered block  10 . In this case, it may be desirable to slightly offset the projections  44  with respect to the core  32  (i.e., such that D1≠D2) so as to provide zero offset when the projections  44  abut the front wall inside surface  18  or the rear wall inside surface  24  of an adjacent-tiered block  10 .  
         [0043]     One of ordinary skill in the art should readily appreciate that the volume of the core  32  can vary, but is preferably maximized to decrease the weight and material cost of the block  10  without impairing the strength, integrity and manufacturability of the block  10 . Similarly, the actual shape and dimensions of the core  32  can vary, provided the core  32  maintains the ability to receive the lug-shaped projections  44  of another block  10 , as will be described later.  
         [0044]     Table 1 lists dimensions for a representative embodiment:  
                               TABLE 1                                       Length L F  of front wall   12   inches           Length L R  of rear wall   9   inches           Width W of block   7   inches           Angle A   12°           Lug height H L     {fraction (5/16)}   inch           Lug width W L     1⅜   inch           Radius of lug R L     ¼   inch           Length of core L C     6   inches           Width of core W C     1½   inches           Radius of core R c     ¾   inch           D1   ¾   inch           D2   ¾   inch           D3   3¾   inches           D4   3¼   inches           Groove G   ⅛   inch                      
 
         [0045]     The block  10  configuration enables a fastening system that provides simple construction and automatic wall alignment. The like-shaped blocks  10  are sized and configured to be laterally aligned in an abutting side-by-side engagement, and vertically aligned in a staggered, stacked manner so that one block  10  rests atop two other blocks  10 .  
         [0046]     When arranged in this manner, the blocks form a multi-tiered wall (W), such as the wall W shown in  FIG. 7 . With reference to  FIG. 8 , the wall W is typically constructed one tier or course at a time. Once a lower course  46  (represented in phantom lines in  FIG. 8 ) is set in place, an upper course  48  (represented in solid lines in  FIG. 8 ) is placed on top of it. The blocks  10  forming the lower course  46  form a generally horizontal platform upon which the upper course  48  can be stacked.  
         [0047]     An interlocking fit is achieved between the like-shaped blocks  10  in adjacent upper and lower courses  48  and  46 . Each block  10  in the upper course  48  is laid in a staggered manner relative to the lower course  46  so that the upper block  10  is placed atop two lower blocks  10 . Each block  10  is also placed such that one of its lug projections  44  extends into and is received by the open core  32  of an adjacent block  10  in an adjacent course  46  or  48 . This interlock limits forward or backward movement of blocks  10  in one course  46  or  48  relative to the blocks  10  of an adjacent course  46  or  48 . This arrangement also limits sideways or lateral movement of blocks  10  in one course  46  or  48  relative to the blocks  10  of the adjacent course  46  or  48 .  
         [0048]     The first course may be laid such that the lower surface  36  and projections  44  are positioned facing upward (i.e., with upper surface  34  facing downward). Upward positioning of the projections  44  may be desirable if the first course is to be laid on a hard or finished surface, e.g., on a patio or deck  50 , as shown in  FIG. 7 . In this embodiment, the subsequent courses may all be similarly laid with the lower surface  36  and projections  44  facing upward, such that each projection  44  extends into and is received by the open core  32  of an adjacent upper block  10 . That is, the upper surface  34  of each block  10  in each stacked, upper course  48  is placed on and rests on the lower surfaces  36  of the blocks  10  in the lower course  46  upon which it is placed.  
         [0049]     Alternatively, subsequent courses may all be laid with the projections  44  facing downward, such that each projection  44  extends into and is received by the open core  32  of an adjacent lower block  10 . That is, the lower surface  36  of each block  10  in each stacked, upper course  48  is placed on and rests on the upper surfaces  34  of the blocks  10  in the lower course  46  upon which it is placed. The final course is desirably laid with the projections  44  facing downward regardless of whether the previous courses were laid with the projections  44  facing upward or downward to present the flat or smooth upper surfaces  34  of the blocks  10  forming the top course, thereby eliminating the need to cut or otherwise remove the projections  44  from the blocks  10  forming the top course.  
         [0050]     Alternatively, the first course may be laid with the lower surface  36  and projections  44  positioned facing downward (i.e., with upper surface  34  facing upward). Downward positioning of the projections  44  may be desirable if the first course is to be laid on soil or other surface in which the projections  44  may be extended to further anchor the first course blocks  10 . If the first course is laid with the projections  44  facing downward, the subsequent courses are preferably all laid with the projections  44  facing downward. This arrangement also presents the flat or smooth upper surfaces  34  of the blocks  10  forming the top course.  
         [0051]     With reference again to  FIG. 8 , in each course, adjacent like-shaped blocks  10  may be laterally inversely aligned so that the front wall  14  of one block  10  lies adjacent the rear wall  20  of the adjacent block  10 . The core  32  of a block  10  is positioned to receive the first projection  44  of an overlying block  10  and the laterally adjacent block  10  is positioned to receive the second projection  44  of the same overlying block  10 . The placement of the projections  44  and the core  32  with respect to the front and rear wall outside surfaces  22  and  28  can be varied to provide no offset dimension and to permit construction of an essentially straight or linear wall or wall portion W L , as shown in  FIG. 8 .  
         [0052]     When the core  32  is spaced essentially equidistant between the front and rear wall outside surfaces  22  and  28 , the core  32  of a block  10  is positioned to receive the first projection  44  of an overlying block  10  in the retaining wall W in an abutting relation to the inside surface  24  of the front wall  14  of the bock  10  and the core  32  of an inversely-aligned and laterally-adjacent block  10  is positioned to receive the second projection  44  of the same overlying block  10  in an abutting relation to the inside surface  24  of the rear wall  20  of the laterally adjacent block  10 . Alternatively, when the core  32  is spaced essentially equidistant between the front and rear wall outside surfaces  22  and  28 , the core  32  of the block  10  is positioned to receive the first projection  44  of an overlying block  10  in the retaining wall W in an abutting relation to the inside surface  24  of the rear wall  20  of the bock  10  and the core  32  of an inversely-aligned and laterally-adjacent block  10  is positioned to receive the second projection  44  of the same overlying block  10  in an abutting relation to the inside surface  18  of the front wall  14  of the laterally adjacent block  10 .  
         [0053]     As seen in  FIGS. 9-11 , laterally inversely-aligned blocks  10  may also be arranged to construct a wall W having an essentially 90° angle. Laterally-adjacent blocks  10  may be broken along a score line  38  (with broken away sections represented in phantom in  FIGS. 9 and 10 ) to form an end block  40  presenting a flat side end surface  42 .  FIG. 9  illustrates one arrangement (C1) of blocks  10  suitable for forming an angle.  FIG. 10  illustrates another arrangement (C2) of blocks  10  suitable for forming an angle. Beginning with either a C1 or a C2 course, C1 and C2 courses can be alternated and staggered as shown in  FIG. 11  (with the C1 course represented in solid lines and the C2 course represented in phantom lines) to construct an angular wall W of a desired configuration.  
         [0054]     As shown in  FIG. 12 , in each course  46  and  48 , like-shaped blocks  10  may also be laterally similarly or uniformly aligned so that the front wall  14  of one block  10  lies adjacent the front wall  14  of the adjacent block  10 . This arrangement permits the construction of an essentially straight or linear wall or wall portion W L  in which the side walls  26  of laterally adjacent blocks  10  define an angle B, as  FIG. 12  also shows.  
         [0055]     To accommodate a variety of landscapes and individual design plans, it is often desirable to construct a wall W in which at least a portion is of a curved or arcuate configuration. As seen in  FIGS. 13 and 14 , like-shaped blocks  10  may also be laterally similarly or uniformly aligned to form a curved wall portion W C  by decreasing angle B. As illustrated in  FIG. 13 , each side wall  26  of a block  10  can be placed so as to contact or abut along its entire length a side wall  26  of a laterally adjacent block  10 . In this arrangement, angle B=0° and the curved portion W C  will have a minimum radius R 1 .  
         [0056]     Alternatively, as illustrated in  FIG. 14 , blocks  10  can be placed such that the side walls  26  of laterally adjacent blocks are not in contact along the entire length of the laterally adjacent side walls  26 . In this arrangement the curved portion W C  will have a radius R 2  greater than the minimum radius R 1 , such that R 2 &gt;R 1 . It will be readily apparent to one of skill in the art that angle B may be selected and varied so as to provide a desired degree of curvature.  
         [0057]     Curved portions W C  may be arranged in either a convex or a concave manner. The degree of curvature may also be selected to provide a low radius curve, a medium radius curve, or a high radius curve. In addition, the blocks  10  can be arranged to gradually or rapidly increase or decrease the radius of the curvature to accommodate a specific setting, landscape or purpose. It is contemplated that blocks  10  may be aligned to form a wall W having both straight portions and curved portions W L  and W C  (see  FIG. 14 ).  
         [0058]     With reference again to  FIG. 7 , the top course of blocks  10  in the wall W is preferably capped by a series of cap stones  52  to cover the open cores  32  of the blocks  10  that form the top course or portion of the top course. The cap stones  52  may be of similar size and configuration to blocks  10 , but without a core  32 . Alternatively, the cap stones  52  may be of an alternative size and/or configuration otherwise adapted for placement over the top course. The cap stones  52  can be glued or otherwise adhered to the upper surface  34  of the top course of blocks  10 , e.g., by masonry adhesive.