Patent Abstract:
Construction blocks for use in constructing retaining walls, embankment stabilizing matrixes, planters, waterway protection walls, and similar structures include a generally C-shaped block, a straight block, a generally Z-shaped block, and a generally S-shaped block. The blocks have a center section having a length X. Except for the straight block, wings project outwardly from each end of the center section. The wings have a length ½X and extend from the centerline of the center section at an angle of 120 degrees. The blocks include grooves on their upper surfaces and tongues that project from their lower surfaces. The grooves and tongues are interconnected when blocks are superimposed so as to provide a stable structure. In addition, the ends of the wings include openings into which dowels can be inserted in order to connect adjacent blocks and thereby provide additional stability. The blocks are attractive, strong, and inexpensive to manufacture. They can be connected securely to each other without mortar. Moreover, the blocks are sufficiently compact and lightweight that they can be carried and installed by only one or two workers.

Full Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to construction blocks and, more particularly, to the use of such blocks to build retaining walls, embankment stabilizing matrixes, planters, ponds for aquatic plants, waterway protection walls, and similar structures. 
     2. Description of the Prior Art 
     There are numerous construction blocks and retaining wall systems in the prior art. See, for example, the patents to Risi et al., U.S. Pat. No. 4,490,075 and Moore, U.S. Pat. No. 3,269,125. A problem with prior construction blocks and structures built therefrom is that the blocks tend to be unduly complex, in many cases requiring heavy capacity lifting equipment to handle them. The blocks often are more expensive to manufacture than desired. Furthermore, prior art blocks often can be used to build only one type of structure, for example, a retaining wall. 
     Desirably, a construction block would be available that would be simple in design, capable of being handled by one person, and usable to construct a wide variety of structures. Preferably, any such structure could be assembled easily without the need for mortar to hold the blocks together. In addition, any such construction block and resulting structures desirably would be attractive so that their use for residential or architectural purposes would be encouraged. 
     SUMMARY OF THE INVENTION 
     In response to the forgoing concerns, the present invention provides a new and improved construction block from which various structures can be made. In order to construct a wide variety of structures, several different forms of the construction block are provided. 
     The most basic construction block according to the invention is a generally C-shaped member that, when assembled with two other blocks, forms a hexagonal cell with sides of 30 inches. Each block includes an elongate center section approximately 30 inches in length from which a pair of 15-inch wings extend at an included angle of 120 degrees. The upper surface of the center section and the wings is provided with a groove, while a tongue projects from the lower portion of the center section and the wings. Accordingly, the blocks can be stacked atop each other and shifting will be prevented by the interaction of the tongues and grooves. Small openings are provided in the end faces of the wings so that dowels can be inserted therein as a further aid to prevent relative movement between adjacent blocks. 
     Other construction blocks according to the invention include a generally Z-shaped block with an elongate center section having one wing extending from one end of the center section at an included angle of 120 degrees and with a second wing extending from the other end of the center section, on the opposite side of the center section, at an included angle of 120 degrees the other way. A third construction block according to the invention is substantially identical to the second-described block, but with the wings reversed to form generally an S-shape. A fourth variation of the construction block according to the invention employs only an elongate center section with notched end faces. The notches are cut at 30 degrees and 60 degrees from the centerline of the center section. This block will lock into the previously described C-shaped block to allow offset vertical stacking. 
     By using construction blocks according to the invention, a variety of sturdy, inexpensive structures can be built by only one or two workers. The blocks can be assembled easily without the need for mortar to hold the blocks together. The basic hexagonal cell can be used to make planters or small ponds for aquatic plants. Retention walls, either vertical or terraced, can be created by using different ones of the construction blocks to fit the landscape at hand. Freestanding walls of various shapes also can be built. The walls can be used as lake or river bank liners or temporary levies to control flooding. The blocks also can be used to quickly construct an inexpensive, sturdy, culvert retention wall. 
     The foregoing and other features and advantages of the invention will be apparent from the description and claims that follow, taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of generally C-shaped construction blocks according to the invention assembled to form a hexagonal tree planter; 
     FIG. 2 is a perspective view of a portion of two of the blocks of FIG. 1, showing the blocks in a separated position with an interconnecting dowel disposed therebetween; 
     FIG. 3 is an end view of one of the construction blocks of FIG. 1; 
     FIG. 3A is a side elevation view of a portion of a construction block according to the invention showing a tongue that terminates a short distance from the end of a wing; 
     FIG. 4 is a view of an alternative construction block according to the invention in which an elongate section includes notched end faces; 
     FIG. 5 is a perspective view of one the blocks of FIG. 1; 
     FIG. 6 is a view of the blocks of FIGS. 4 and 5 assembled to form a terraced retaining wall; 
     FIG. 6A is a view taken along a plane indicated by line  6 A— 6 A in FIG. 6; 
     FIG. 7 is a perspective view of the blocks of FIGS. 4 and 5 assembled to form a serpentine wall; 
     FIGS. 8A and 8B are perspective views of a generally Z-shaped block and a generally S-shaped block according to the invention; 
     FIG. 9 is a view similar to FIG. 7 in which blocks shown in FIGS. 5,  8 A, and  8 B have been assembled to form a serpentine wall; 
     FIG. 10 is a view of a pond for aquatic plants formed by the assembly of the blocks illustrated in FIG. 5; 
     FIG. 11 is a view of the blocks of FIG. 5 spaced apart on a hillside to provide steps; 
     FIG. 12 is a view of a culvert retaining wall constructed of the blocks of FIG. 5; 
     FIG. 13 is a view similar to FIG. 7 showing the wall used as a retaining wall; and 
     FIG. 14 is a view similar to FIG. 13 showing the wall of FIG. 7 used as a retaining wall for a body of water. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIGS. 1-3 and  5 , a generally C-shaped construction block according to the invention is indicated by the reference numeral  10 . The block  10  includes an elongate center section  12  from which a first wing  14  projects at one end, and a second wing  16  projects from the other end. The center section  12  and the first and second wings  14 ,  16  each include upper surfaces  18 A,  18 B, and  18 C, respectively. Similarly, these elements include lower surfaces  20 A,  20 B,  20 C, front walls  22 A,  22 B,  22 C, back walls  24 A,  24 B,  24 C, and longitudinal axes  26 A,  26 B,  26 C. Grooves  28 A,  28 B,  28 C are formed in each of the upper surfaces  18 A,  18 B,  18 C, respectively. Similarly, tongues  30 A,  30 B,  30 C project from the lower surfaces  20 A,  20 B,  20 C, respectively. The wing  14  includes an end face  32 B. The wing  16  includes an end face  32 C. An opening  34 B is formed in the end face  32 B, while an opening  34 C is formed in the end face  32 C. A dowel  36  (FIG. 2) is provided for insertion into the openings  34 B,  34 C. The lower surface  20 C, tongue  30 C, end face  32 C, and opening  34 C are not illustrated in the Figures, but they correspond to lower surfaces  20 A,  20 B, tongues  30 A,  30 B, end faces  32 A,  32 B, and openings  34 A,  34 B, respectively, which are illustrated in the Figures. 
     In the preferred embodiment, the block  10  is formed of concrete in a molding operation. In order to facilitate manufacture and for good strength, it is preferred that the upper and lower surfaces  18 ,  20  and the front and back walls  22 ,  24  be flat, straight and perpendicular, thereby generally defining a rectangle in cross-section. The upper and lower surfaces  18 ,  20  should lie in a parallel planes. Similarly, for ease of manufacture and for strength, it is preferred that the groove  28  have sides that taper at approximately a 15 degree angle from the vertical to a flat bottom. Preferably, the bottom of the groove  28  is approximately 0.75 inch wide, and the opening into the groove  28  is approximately 1.25 inches wide. The tongue  30  should closely match the size and shape of the groove  28  in order to minimize shifting of superimposed blocks  10  relative to each other. Preferably, the end of the tongue  28  is approximately 0.625 inch wide and the base of the tongue  30  is approximately one inch wide. The groove  28  and the tongue  30  are approximately 0.875 inch and 0.625 inch deep, respectively. The opening  34  is approximately 0.75 inch in diameter and approximately 3.0 inches deep. The dowel  36  is slightly less than 0.75 inch in diameter, and it should have an overall length of slightly less than six inches. 
     In the preferred embodiment, the front wall  22 A is 30 inches long, and the front wing walls  22 B,  22 C are 15 inches long. The included angle between the axes  26 A,  26 B and  26 A,  26 C are each 120 degrees. These angular relationships are indicated in FIG. 5 by the reference numerals  38 A,  38 B, respectively. It is expected that the front and back walls  22 ,  24  will be 7.75 inches high (the height of a conventional concrete block), and the upper and lower surfaces  18 ,  20  will be approximately three inches wide. 
     When the block  10  is made of concrete to the forgoing dimensions, it will weigh approximately 105 pounds, not including any internal reinforcement such as wire mesh. Although internal reinforcement has been found to be unnecessary for most applications, a suitable wire mesh is commercially available under the trademark DURA WALL or DURA BAR. DURA WALL and DURA BAR wire mesh is supplied in 10 foot lengths, five feet of which is needed for each block  10 . Those skilled in the art will appreciate that the block  10  can be manufactured of other materials and/or other dimensions, if desired, but the preferred material and dimensions have been found to be effective and desirable because of ergonomic weight limitations. Other materials that can be used, depending on the user&#39;s needs, include various plastics such as polyethylene, concrete filled with plastic pellet aggregate, cinders, baked slate aggregate sold under the trademark SOLITE, vermiculite, or ore slag, or even plastic with embedded pressure-treated wood cores. Use of these alternate materials will produce somewhat lighter blocks; for example, when cinder-filled concrete is used, the block  10  will weigh under 90 pounds. The block  10  when made of concrete filled with SOLITE aggregate will weigh approximately 75-80 pounds. 
     Referring now to FIGS. 4,  6 , and  6 A, a straight block  40  according to the invention is shown. Block  40  is similar to the center section  12  of the block  10  without the first and second wings  14 ,  16 . Because the block  40  is similar in size and shape to the center section  12 , like reference numerals will be used to describe the various components of the block  40 . Accordingly, the block  40  has an upper surface  18 A, a lower surface  20 A, a front wall  22 A, a back wall  24 A, a longitudinal axis  26 A, a groove  28 A formed in the upper surface  18 A, and a tongue  30 A projecting from the lower surface  20 A. Unlike the center section  12 , however, the block  40  has notched end faces  42 ,  44 , each of which has an angled surface  46  and an intersecting angled surface  48 . The surfaces  46 ,  48  are disposed at right angles to each other. The angled surfaces  46  are disposed at an angle of 30 degrees relative to the longitudinal axis  26 A, while the angled surfaces  48  are disposed at an angle of 60 degrees relative to the longitudinal axis  26 A. The front face  22 A of the block  40  is 26.5 inches long, while the back face  24 A is 30 inches long. 
     Referring to FIG. 8A, another alternate block according to the invention is indicated by the reference numeral  60 . The block  60  is generally Z-shaped. The block  60  includes a center section  62  and first and second wings  64 ,  66 . Because the center section  62  and the first and second wings  64 ,  66  are substantially similar to the center section  12  and the first and second wings  14 ,  16 , reference numerals from the section  12  and the first and second wings  14 ,  16  will be carried over to the section  62  and the first and second wings  64 ,  66 , where appropriate. 
     The primary difference between the block  60  and the block  10  is that the first wing  64  is disposed on the opposite side of the longitudinal axis  26 A from the first wing  14 . The angle between the longitudinal axis  26 A of the center section  62  and the longitudinal axis  26 B of the first wing  64  is 240 degrees. 
     Referring now to FIG. 8B, yet another alternative embodiment of the block  10  is indicated by the reference numeral  70 . The block  70  includes a center section  72 , a first wing  74 , and a second wing  76 . The block  70  is generally S-shaped. As with the block  60 , the block  70  is substantially similar to the block  10 , except that the second wing  76  is disposed on the opposite side of the longitudinal axis  26 A from the second wing  16 . The angle between the longitudinal axis  26 A and the longitudinal axis  26 C for the center section  72  and the second wing  76  is 240 degrees. 
     Preferably the cross-section of each of the blocks  10 ,  40 ,  60 , and  70  is constant throughout its length. 
     It is expected that various ones of the blocks  10 ,  40 ,  60 , and  70  may be stacked atop each other to form structures in which all portions of the blocks are not superimposed, such as that indicated in FIG.  6 . In order to prevent interference between the tongues  30  and the upper surfaces  18  at that location where the tongues  30  depart from the grooves  28 , two possible modifications from that configuration shown in the Figures can be made. In one approach, as shown is FIG. 3A, the tongues  30 A,  30 B, and  30 C can be terminated approximately three inches short of the intersection between the first and second wings as well as approximately three inches short of the ends of the wings. In the other approach, small channels  80  (FIG. 5) can be formed into the upper surfaces  18  at the intersection between the center section  12  and each of the wings  14 ,  16 . The channels  80  should be slightly wider and deeper than the tongues  30 . The channels  80  will accept the tongues  30 A,  30 B,  30 C, thereby preventing any interference. The use of the channels  80  is preferred over shortening the tongues  30 . 
     Examples Of Structures That Can Be Built With The Blocks  10 ,  40 ,  60 , and  70 . 
     1. Planter 
     Referring to FIG. 1, three of the blocks  10  can be assembled to form a hexagonal planter. The end faces  32 B,  32 C are connected by dowels  36 , as indicated in FIG. 2, to provide a secure connection between adjacent blocks  10 . The tongues  30 A,  30 B,  30 C will be pressed into the ground providing further stability for the blocks  10 . 
     2. Freestanding Wall 
     Referring to FIG. 7, a freestanding wall employing the blocks  10  and  40  is shown. The wall has three courses of blocks, although additional courses of blocks could be added to increase the height of the wall, if desired. 
     Another version of the freestanding wall is shown in FIG.  9 . In FIG. 9, the wall is made by using combinations of blocks  10 ,  60 , and  70 . The wall as shown in FIG. 9 can be made higher than the wall shown in FIG. 7 because the interface between the end faces  32 B,  32 C of the blocks  10 ,  60 ,  70  of a given course are offset from the comparable interfaces of vertically adjacent courses so as to provide a sturdier structure than that shown in FIG.  7 . 
     3. Terraced (Staircase) Retaining Wall 
     As shown in FIGS. 6 and 6A, blocks  10  and  40  can be assembled in a manner similar to that shown in FIG. 7 to produce a terraced, or staircase, retaining wall. This type of retaining wall is used for sloping hillsides. As can be seen in FIG. 6, each course is shifted laterally relative to the one below it so that the center sections  12  always are superimposed above a straight block  40 . This construction is made possible either by providing channels  80  for the upper surfaces  18  or by limiting the length of the tongues  30 A,  30 B,  30 C, as described previously. As shown in FIG. 6, this arrangement of blocks  10 ,  40  produces a retaining wall having a honeycomb appearance. 
     4. Pond for Aquatic Plants 
     Referring to FIG. 10, a small pond can be formed by utilizing the planter of FIG.  1  and draping a water-impervious sheet liner over the open containment formed thereby. The sheet is pressed into place along the lower edges of the opening. Thereafter, a second course of blocks  10  is placed above the first course, trapping the sheet liner between the superimposed blocks  10 . The sheet is trimmed along the outer edges in order to present a clean appearance. Thereafter, the enclosure can be filled with water up to the level defined by the upper surface of the first course of blocks  10 . As with the wall shown in FIG. 9, the interface between the end faces  32 B,  32 C of the upper course of blocks  10  is offset from the comparable interface of the lower course of blocks  10 . 
     5. Stair Steps On An Incline 
     Referring to FIG. 11, a plurality of blocks  10  are spaced apart on an incline. The blocks  10  are set into the ground so that they will not move. The ground between the upper surface  18  of one block  10  and the lower surface of the adjacent block  10  is filled by dirt, gravel, small stones, pre-formed concrete panels, and the like. The blocks  10  thus form the riser portion of the stair steps for the incline. Preferably, the blocks  10  that are used in this manner will be manufactured without the groove  28  in the upper surface  28 . Similarly, the blocks  10 ,  40 ,  60 ,  70  can be formed without the groove  28  when the blocks  10 ,  40 ,  60 ,  70  are used as the upper course of a structure. 
     6. Culvert Retention Wall 
     Referring to FIG. 12, a culvert drain pipe is shown. The drain pipe is surrounded by a plurality of blocks  10  that are positioned atop each other so as to be disposed upon either side of the culvert pipe and on top the culvert pipe. In order to form the retention wall shown in FIG. 12, it is necessary to remove a portion or all of the first wings  14  and the second wings  16  on that side of the blocks  10  adjacent the pipe. By modifying the blocks  10  in this manner, the center sections  12  can be positioned close enough to receive a superimposed block  10 . 
     7. Planter Retaining Wall 
     Referring to FIG. 13, a planter retaining wall is shown. The wall is identical to the freestanding wall shown in FIG. 7 except that in this instance it retains dirt so that a planter can be formed. 
     8. Retention Wall For Ponds And Other Bodies Of Water 
     Referring to FIG. 14, the wall of FIG. 7 is used to define the interface between a bank and a body of water such as a pond, creek, and the like. 
     As will be apparent from the foregoing description, the construction blocks according the invention can be used to construct a wide variety of structures. Because the blocks are relatively small and simple in design, they can be manufactured inexpensively. They can be used for residential or commercial purposes and, when constructed into shapes such as those shown in the drawings, will produce attractive, sturdy structures. Because of their size and weight, these structures can be assembled without lifting equipment and can be quickly installed in remote locations with little surface or footing preparation. 
     Although the invention has been described in its preferred form with a certain degree of particularity, it will be understood that the present disclosure of the present embodiment has been made only by way of example, and that various changes may be resorted to without departing from the true spirit and scope of the invention as hereinafter claimed. It is intended that the patent shall cover, by suitable expression in the appended claims, whatever features of patentable novelty exist in the invention disclosed.

Technology Classification (CPC): 4