Abstract:
A concrete block that can be placed in a wall constructed from a plurality of concrete blocks to accent the wall face. The block has a relief formed on a depressed field on the front of the block. The depressed field is preferably surrounded by a border that projects forwardly beyond the depressed field, and a portion or all of the relief projects forwardly beyond the border. One or more of the blocks of the invention can be placed as desired in the wall to break up the uniformity of the wall face and soften the plane of the wall, tie the wall in with the surrounding landscape, or to add interest to an otherwise uniform wall face.

Description:
FIELD OF THE INVENTION  
         [0001]    The invention relates generally to concrete blocks. More specifically, the invention relates to concrete blocks suitable for use in landscaping applications, such as retaining walls, and other architectural applications.  
         BACKGROUND OF THE INVENTION  
         [0002]    It has become common to use concrete blocks for constructing structures in a variety of applications. One example is in landscaping applications, where such blocks are used to create, for example, retaining walls, ranging from small tree ring walls and garden edging walls to comparatively large structures.  
           [0003]    In a retaining wall, as well as in other structures constructed from concrete blocks, the front face of each block, which often has a generally similar appearance to the front faces of the other blocks, is typically visible in use. The appearance of the resulting wall face created from such blocks can tend to have a uniformity or “sameness”. While uniformity is not undesirable in many applications, in some settings, such as a garden, the wall face may appear to some to be too harsh, imposing, or out-of-place. Therefore, in some instances, it would be desirable to break up the uniformity of the wall face.  
           [0004]    It is known to mold blocks within a mold, in which a mold surface imparts a decorative pattern to a corresponding surface of the block to enhance the visual appeal of the block. Examples include U.S. Pat. Nos. D20,287; D21,522; 451,799; 765,086; 985,353; and 1,166,312.  
           [0005]    However, there is a continuing need for a concrete block that includes at least one decorated surface, so that when the block is used in, for example, a retaining wall constructed from a plurality of concrete blocks, the decorated surface breaks up the uniformity of the wall face and softens the expansive plane created by the wall face.  
         SUMMARY OF THE INVENTION  
         [0006]    The invention relates to a concrete block that can be placed in a wall that is constructed from a plurality of concrete blocks to accent the wall face. The concrete block is preferably a retaining wall block for use in a retaining wall in landscape applications. However, the block could be used in other walls that are constructed from concrete blocks.  
           [0007]    One or more of the blocks of the invention can be placed as desired in the wall to break up the uniformity of the wall face and soften the plane of the wall, tie the wall in with the surrounding landscape, or to add interest to an otherwise uniform wall face. The blocks can be placed randomly in the wall, or arranged in a pattern in one or more courses of the wall.  
           [0008]    In the preferred embodiment, the block has a front face composed of one or more decorative features. The decorative feature is preferably integrally formed on the block during formation of the block. Thus, the decorative feature will have the appearance of having been carved in the face of the block.  
           [0009]    Examples of decorative features that could be used on the inventive block includes leaves, flowers, trees, various insects and animals including butterflies and dragonflies, human faces, scenes of nature, letters, and numbers. Numerous other decorative features could be used within the scope of the invention.  
           [0010]    In the preferred embodiment, the decorative feature comprises a relief formed on a depressed field on the front of the block. The depressed field is preferably surrounded by a border that projects forwardly beyond the depressed field, and a portion or all of the relief projects forwardly beyond the border. The border serves as a frame for the decorative relief. In addition, the border helps to protect the relief from being damaged, for example during handling and transport of the block. The relief could also be designed such that no portion thereof projects forwardly beyond the border.  
           [0011]    The relief will appear to have been carved out of an undecorated block, and the border will appear as though it is a border of remaining stone. However, it is contemplated that the relief could overlap one or more portions of the border, thereby obscuring the border in that location. Alternatively, it is contemplated that where the relief is expected to overlap the border, the border could be removed in those areas.  
           [0012]    In one embodiment according to the invention, the block comprises at least one locator protrusion which interacts with one or more adjacent blocks when laid up in a wall to aid in positioning and retaining the block relative to the adjacent blocks. The locator protrusion preferably comprises a flange that is integrally formed with the block adjacent the rear of the block to provide shear resistance and set-back with respect to blocks in the next lower course of blocks in the wall.  
           [0013]    In another embodiment according to the invention, the block is configured as an insert to be inserted into an already existing wall. In this case, the block insert preferably has a depth between the front and rear thereof that is less than the depth of the other blocks in the wall. This permits the block insert to be inserted into an opening provided in the wall face, without requiring dismantling of the wall. The block insert can be secured in place using an adhesive.  
           [0014]    These and various other advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages and objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying description, in which there is described a preferred embodiment of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    [0015]FIG. 1 is a perspective view of a block according to the present invention.  
         [0016]    [0016]FIG. 2 is a front view of the block of FIG. 1.  
         [0017]    [0017]FIG. 3 is a side view of the block of FIG. 1.  
         [0018]    [0018]FIG. 4 is a top view of the block of FIG. 1.  
         [0019]    [0019]FIG. 5 is a bottom view of the block of FIG. 1.  
         [0020]    [0020]FIG. 6 is a perspective view of a block according to a second embodiment of the invention.  
         [0021]    [0021]FIG. 7 is a view of a portion of a retaining wall that depicts how blocks according to the invention can be used to accent the wall. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0022]    A concrete block  10  according to the present invention is illustrated in FIGS.  1 - 5 . The block  10  is illustrated as being a retaining wall block for use in a retaining wall. It is to be realized, however, that the concepts disclosed herein are applicable to other types of concrete blocks.  
         [0023]    The block  10  comprises a block body having a front  12 , a back  14 , a top surface  16 , a bottom surface  18 , a first side  20 , and an opposed second side  22 . The block  10  is formed from a cured, dry cast, no slump masonry concrete. Dry cast, no slump masonry concrete is well known in the art of retaining wall blocks.  
         [0024]    The front  12  of the block  10 , as illustrated in FIGS.  1 - 5 , is provided with a pre-determined three-dimensional relief or pattern  24  on a depressed field  26 , which is surrounded at least partially by a border  28 . In the preferred embodiment, the border  28  includes a top portion  30 , a bottom portion  32 , and first and second side portions  34 ,  36 , so that the border  28  entirely surrounds the depressed field  26  and the relief  24 . However, the border  28  could surround only portions of the field  26  and relief  24  if desired. Moreover, the relief  24  is illustrated as intersecting the border  28  at several locations, for example locations A, B and C. At several locations, for example locations A and B, the relief  24  overlaps the border  28 . However, the relief  24  could be entirely within the border  28  if desired.  
         [0025]    In the illustrated embodiment, the top and bottom portions  30 ,  32  of the border  28  intersect the side portions  34 ,  36  at inner corner junctions  38   a, b, c, d  that are radiused. In addition, the top portion  30  of the border  28  is adjacent and intersects the top surface  16 , the bottom portion  32  is adjacent and intersects the bottom surface  18 , the side portion  34  is adjacent and intersects the side  20 , and the side portion  36  is adjacent and intersects the side  22 . Other configurations of the border  28  are possible within the scope of the invention. For example, one or more of the border portions  30 ,  32 ,  34 ,  36  could be arranged in a non-contiguous relationship with its respective block surface.  
         [0026]    With reference to FIG. 2, the depressed field  26  includes surface portions  40  that are not provided with the relief  24 . It is preferred that these surface portions  40  be generally smooth and without ornamentation, which helps make the relief  24  “stand-out” from the surrounding block structure. However, it is contemplated that the surface portions  40  could be textured.  
         [0027]    As shown in FIGS.  1 - 3 , the border  28  projects forwardly beyond the surface portions  40  of the depressed field  26 . In addition, it is preferred that at least a portion of the relief  24  projects forwardly beyond the border and, at certain locations as discussed above, the relief  24  overlaps portions of the border, as best seen in FIGS. 1 and 3- 5 . With this construction, the border  28  helps to frame the relief  24 , while the relief  24  on the smooth, depressed field  26  helps the relief “stand-out” and make it readily discernible. If desired, the entire relief  24  could project forwardly beyond the border  28 . Moreover, the depressed field  26  could extend into the block from the border  28  toward the back  14  a greater or lesser extent than shown in FIGS.  1 - 5 , depending upon the look one seeks to achieve.  
         [0028]    In the illustrated embodiment, the front  12  is curved outwardly into a convex shape between the sides  20 ,  22 . However, the front  12  can have other shapes between the sides  20 ,  22 , including multi-faceted or a single plane as are frequently seen in retaining wall blocks.  
         [0029]    The relief  24 , depressed field  26  and border  28  are preferably imparted to the front  12  during molding of the block  10  by a mold surface having a pattern that is the mirror image of the relief  24 , depressed field  26  and border  28  to be formed. The use of a mold surface to impart a pattern to a block surface is well known in the art of retaining wall blocks. An example of a process that could be used to produce the relief  24 , depressed field  26  and border  28  is disclosed in application Ser. No. 10/038,639, filed on Jan. 4, 2002, and entitled MASONRY BLOCK AND METHOD OF MAKING SAME.  
         [0030]    The relief  24 , depressed field  26 , and border  28  that are imparted to the front  12  can vary depending upon the desired appearance of the block front. The particular relief that is used will be selected based on what is thought to be visually pleasing to users of the blocks. By way of example, the relief  24  illustrated in FIGS.  1 - 5  simulates oak leaves and acorns. Other examples of patterns include leaves, flowers, trees, various insects and animals including butterflies and dragonflies, human faces, scenes of nature, letters, numbers, and combinations thereof. Endless possibilities are available. By providing a plurality of mold surfaces with a variety of different patterns, the resulting relief on blocks can be varied by changing mold surfaces.  
         [0031]    The back  14 , top and bottom surfaces  16 ,  18 , and the sides  20 ,  22  of the block  10  can have numerous configurations. In the block  10  illustrated in FIGS.  1 - 5 , the back  14 , top and bottom surfaces  16 ,  18 , and the sides  20 ,  22  are of a known construction. The back  14  of the block  10  is generally planar between the sides  20 ,  22  and generally perpendicular to the top and bottom surfaces  16 ,  18 . However, it is contemplated that the back  14  could deviate from planar, such as by being provided with one or more notches or provided with one or more concavities, while still being within the scope of the invention.  
         [0032]    The top surface  16  has at least a contact portion that is generally horizontal and generally planar which, in use, is contacted by a bottom surface of at least one block in an upper course of blocks. In the illustrated embodiment, the top surface  16  is generally horizontal and generally planar over its entire extent, and free of cores intersecting the upper face  16 . When the block  10  is disposed in a wall, the top surface  16  is in a generally parallel relationship to the top surfaces of the other blocks in the wall.  
         [0033]    The bottom surface  18  of the block  10  is formed so as to be suitable for engaging the top surface of a block(s) in the course below to maintain the generally parallel relationship between the top surfaces of the blocks when the blocks are stacked into courses. The bottom surface  18  has at least a contact portion that is generally horizontal and generally planar that is configured so that, in use, the contact portion rests upon at least a portion of a top surface of a block disposed in a course below the block.  
         [0034]    In the illustrated embodiment, the bottom surface  18  includes a pair of recesses  42   a ,  42   b , but is otherwise generally planar and horizontal so that it is generally parallel to the top surface  16 . However, other bottom surfaces can be used, including a bottom surface that is entirely horizontal and planar, or that includes one or more concave portions over portions of the bottom surface  18 .  
         [0035]    The sides  20 ,  22  of the block  10  are generally vertical and join the top and bottom surfaces  16 ,  18  and join the front and back  12 ,  14 , as seen in FIGS.  1 - 5 . At least a portion of each side  20 ,  22  converges toward the opposite side as the sides extend toward the back  14 . Preferably the entire length of each side  20 ,  22  converges starting from adjacent the front  12 , with the sides  20 ,  22  being generally planar between the front  12  and back  14 . However, it is possible that the sides  20 ,  22  could start converging from a location spaced from the front  12 , in which case the sides  20 ,  22  would comprise a combination of straight, non-converging sections extending from the front  12  and converging sections leading from the straight sections to the back  14 .  
         [0036]    Alternatively, the block  10  can be provided with only one converging side or side portion, with the other side being substantially perpendicular to the front and back  12 ,  14 . A block with at least one converging side permits serpentine retaining walls to be constructed.  
         [0037]    The block  10  can include one or more locator protrusions integrally formed on the top or bottom surface  16 ,  18 . In the embodiment illustrated in FIGS.  1 - 5 , the locator protrusion comprises a flange  44  that extends below the bottom surface  18  of the block adjacent to the back  14 , as seen in FIGS.  1 - 3  and  5 . The flange  44  includes a rear surface that is continuous with the back  14  of the block. The flange  44  is designed to abut against the rear face of a block(s) in the course below the block  10  to provide a predetermined set-back from the course below and to provide course-to-course shear strength.  
         [0038]    A second embodiment of a block  100  according to the invention is illustrated in FIG. 6. The block  100  is designed as an insert that can be inserted into a suitable space provided in a pre-existing wall, without requiring dismantling of the wall. The block  100  can be secured within the wall using a suitable adhesive.  
         [0039]    The block  100  comprises a block body having a front  102 , a back  104 , a top surface  106 , a bottom surface  108 , a first side  110 , and an opposed second side  112 . The block  100 , like the block  10 , is formed from a cured, dry cast, no slump concrete.  
         [0040]    Moreover, like the block  10 , the front  102  of the block  100  is provided with a pre-determined three-dimensional relief or pattern  114  on a depressed field  116 , which is surrounded at least partially by a border  118 . The front  102  of the block  100  is identical to the front  12  of the block  10  and is, therefore, not further described.  
         [0041]    In this embodiment, the depth X of the block  100  along a straight line between the forwardmost point on the border  118  and the rear  104  is less than the depth of most of the other blocks in the wall into which it is to be inserted. The block  100  preferably has a height and a width that is approximately equal to the height and width of the pre-existing blocks in the wall. This permits the block  100  to be inserted into the wall in an opening formed in the wall. Such an opening can be formed, for example, by unstacking a portion of an existing wall, inserting one or more blocks  100  where desired, and then restacking the wall. An opening could also be formed by, for example, removing the front portion of one of the pre-existing blocks in a wall using, for example, a hammer and chisel.  
         [0042]    [0042]FIG. 7 is a view of a portion of a retaining wall  50  that depicts blocks according to the invention placed in the wall. The blocks can either be a full size block like the block  10 , or a block insert like the block  100 , or a combination of both blocks. The blocks depicted in FIG. 7 are illustrated with an alternative embodiment of a decorative relief that can be provided on the front of the block.  
         [0043]    The above specification and examples provide a complete description of the manufacture and use of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.