Patent Description:
Hardscaping structures are useful in many hardscaping or landscaping endeavors, such as decoration, soil retention, protection of natural and artificial structures, bases for other construction, and other related projects. For example, homeowners may desire a structure that resembles natural rock surface. However, natural rock is often difficult to work with, hard to combine with other pieces, and expensive to transport. Naturally-occurring pieces usually need to be treated or manipulated to fit the desired size, shape, and texture that the user wants. Additionally, homeowners want such investments to be long-lasting and require little or no maintenance. Such options are often very heavy, expensive to maintain, and prone to damage.

Previously, manufactured blocks were used to build hardscaping and landscaping walls. Some of these blocks had different structural or aesthetic features, and they could be combined to construct walls or barriers. However, many of them do not offer a "natural" stone look that many customers desire. Additionally, they are often difficult to stack on top of each other or combine with other units. Furthermore, the aesthetic portions are often fragile and get damaged during transportation, installation, or early in their use. It is desired to manufacture hardscaping units that are long-lasting, easy to manufacture, and can replace natural rock while maintaining a natural appearance.

<CIT> describes a method for producing a component with an imitation natural stone surface and the component itself for creating masonry in general, in particular for structures, buildings, fences and the like, especially for walls and walls with a load-bearing and/or heat and sound-insulating function. A malleable, i.e., still soft hardenable imitation natural stone mass is introduced into a hollow mold that is open at the top, the inside of which is structured according to the desired imitation natural stone surface. A carrier stone, which has at least one recess extending from the outside into the interior of the stone, preferably widening and/or sloping, on a side to be provided with the imitation natural stone, is introduced into the imitation natural stone mass in such a way that the latter penetrates into the recess(s), before the mass is hardened. This makes it possible to interlock the applied natural stone imitation layer with the carrier stone by engaging it in the recess(s) and to anchor it in it, thereby achieving a positive connection of the hardened imitation natural stone with the carrier stone material without having to use additional adhesive. The carrier stone, which has grown together with the imitation layer to form a homogeneous brick, has uniform strength throughout.

<CIT> describes a process for making brick-faced block. Colored brick material is laid into a plurality of individual molds of a molding unit to mold at once a plurality of bricks arranged with a predetermined space between each pair of adjacent bricks. Then a base block made of foamed resin and coated with a brick adhesive layer is placed and pressed against the molding unit to bond at once these bricks to the brick adhesive layer. Thereupon the brick adhesive layer is partially exposed to form joints in accordance with the predetermined space between each pair of adjacent bricks. Thereafter, steps of stripping and aging are carried out to form a brick-faced block.

The present invention provides a method of assembling a hardscaping unit in accordance with claim <NUM>. Further embodiments of the invention are defined in the appended claims.

The foregoing summary, as well as the following detailed description of illustrative embodiments of the cover of the present application, will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the cover of the present application, there is shown in the drawings illustrative embodiments. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown. In the drawings:.

Aspects of the disclosure will now be described in detail with reference to the drawings, wherein like reference numbers refer to like elements throughout, unless specified otherwise. Certain terminology is used in the following description for convenience only and is not limiting. The term "plurality", as used herein, means more than one. The terms "a portion" and "at least a portion" of a structure include some of the structure up to the entirety of the structure.

The terms "substantially parallel" and "parallel" as used herein in reference to two elements with respect to each other includes the two elements being close to, but not exactly, parallel to each other and the two elements being exactly parallel to each other. The terms "substantially perpendicular" and "perpendicular" as used herein in reference to two elements with respect to each other includes the two elements being close to, but not exactly perpendicular to each other, and the two elements being exactly perpendicular to each other. The term "fixedly attached" as used herein in reference to a first element and a second element means the first element and the second element cannot be separated from each other without plastically deforming the first element, the second element, or both.

Referring to <FIG>, a plurality of hardscaping units <NUM> may be positioned adjacent to one another to form a wall <NUM>. The wall may be constructed to have a different height H, width W1, depth D, and shape. For example, a wall may be as high, wide, or deep as a single hardscaping unit. Alternatively, a wall may be made up of layers of hardscaping units stacked one on top of another or placed adjacent to one another. A wall may be uniform throughout or may have a different height, width, depth, or shape throughout. A wall may have a straight shape, or it may be constructed to have a curved shape. The number of hardscaping units depicted in <FIG> is not limiting. The wall <NUM> may be configured such that a separate wall can be affixed or positioned adjacently to at least part of the first wall.

Referring to <FIG>, the plurality of hardscaping units <NUM> may include hardscaping units <NUM> of different shapes arranged to form the wall <NUM> with various characteristics. As shown in the illustrated embodiment, the wall <NUM> includes a first side <NUM> and a second side <NUM> that each have an outward facing surface. Each of the first side <NUM> and the second side <NUM> may be straight, bent, curved, or any combination thereof. For example, the wall <NUM> may include a comer <NUM> as shown in the illustrated embodiment. The plurality of hardscaping units <NUM> may be configured and arranged such that the first side <NUM> and the second side <NUM> each have an appearance similar to that of natural stone.

As shown in the illustrated embodiment of <FIG>, the wall <NUM> includes a first side <NUM> and a second side <NUM> that each have an outward facing surface. The wall may include a plurality of corners <NUM> as shown in <FIG>. The hardscaping units <NUM> may include hardscaping units <NUM> of different shapes and sizes.

Referring to <FIG>, a hardscaping unit <NUM> may include a first block <NUM> (also referred to herein as a "backer block") and a second block <NUM> (also referred to herein as a "veneer block") secured to the first block <NUM>. The first block <NUM> is configured to be easy to stack to facilitate efficient building of the wall <NUM>. As shown in the illustrated embodiment, the first block <NUM> may include one or more substantially flat surfaces that are configured to abut other flat surfaces of other first blocks <NUM>, thereby facilitating efficient building of the wall <NUM>.

The second block <NUM> is configured to have an appearance that resembles natural (non-manufactured) stone. Thus the hardscaping unit <NUM> is configured to be quickly and easily stacked to build a wall while also presenting a natural stone appearance. The hardscaping unit <NUM> may be constructed to a variety of sizes and shapes. For example the hardscaping unit <NUM> may be in the shape of a trapezoidal prism. The hardscaping unit <NUM> may also be formed as a rectangular prism, triangular prism, or a variety of other suitable shapes (including non-prism shapes). As shown in the illustrative embodiment the hardscaping unit <NUM> may include one second block <NUM> fixedly attached to one first block <NUM>. Alternatively, the hardscaping unit <NUM> may include a one or more of the second blocks <NUM> each attached to one or more of the first blocks <NUM>.

Referring to <FIG>, the first block <NUM> may be constructed to have one of a variety of shapes and dimensions. For example, the first block <NUM> may be prismatic or pyramidal in shape, including, but not limited to, triangular, rectangular, other geometric and non-geometric shapes. The first block <NUM> includes a front surface <NUM>, a back surface <NUM>, a top surface <NUM>, a bottom surface <NUM>, a first side surface <NUM>, and a second side surface <NUM>. As shown in the illustrated embodiment, the front surface <NUM> may be spaced from, for example opposite to, the back surface <NUM> along a first direction D1. Also as shown in the illustrated embodiment, the top surface <NUM> may be spaced from, for example opposite to, the bottom surface <NUM> along a second direction D2. The first direction D1 may be substantially perpendicular to the second direction D2, as shown in the illustrated embodiment.

The top surface <NUM> and the bottom surface <NUM> may each be substantially planar such that the top surface <NUM> lies substantially in a first plane and the bottom surface <NUM> lies substantially in a second plane. According to one embodiment, the first plane and the second plane are substantially parallel to each other. According to another embodiment, the first plane and the second plane may be non-parallel to each other. The front surface <NUM> and the back surface <NUM> may each be substantially planar such that the front surface <NUM> lies substantially in a third plane and the back surface <NUM> lies substantially in a fourth plane. According to one embodiment the third plane and the fourth plane are substantially parallel to each other. As shown in the illustrated embodiment, the first and second planes may each be substantially perpendicular to the third and fourth planes. According to another embodiment, the third plane and the fourth plane are non-parallel to each other.

The first side surface <NUM> and the second side surface <NUM> may each be substantially planar such that the first side surface <NUM> lies substantially in a fifth plane and the second side surface <NUM> lies substantially in a sixth plane. According to one embodiment, the fifth plane and the sixth plane are non-parallel to each other such that the first side surface <NUM> and the second side surface <NUM> converge along a direction from the front surface <NUM> to the back surface <NUM>. As shown in the illustrated embodiment, the first block <NUM> includes a first length L1 defined by the front surface <NUM> and measured in a third direction D3 that is perpendicular to both the first direction D1 and the second direction D2, and the first block <NUM> includes a second length L2 defined by the back surface <NUM> and measured in the third direction D3.

The converging first and second side surfaces <NUM>, <NUM> may result in the first block <NUM> having a first length L1 that is greater than the second length L2. The first length L1 being longer than the second length L2 may provide an advantage of the first block <NUM> configured to increase the area of the front surface <NUM> while minimizing the material used in and weight of the first block <NUM>. As shown in the illustrated embodiment, the first block <NUM> defines a trapezoidal shape when viewed from above, or in the first plane.

The first block <NUM> has a width W1 measured from the back surface <NUM> to the front surface <NUM> in the first direction D1. The first block <NUM> further has a height H measured from the bottom surface <NUM> to the top surface <NUM> in the second direction D2. According to one embodiment, the first block <NUM> has a first length L1 of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), a second length L2 of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), a width W1 of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), a height H of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), or any combination thereof. According to one embodiment the first block <NUM> may have a first length L1 of about <NUM> (<NUM> inches), a second length L2 of about <NUM> (<NUM> inches), a width W1 of about <NUM> (<NUM> inches), and a height H of about <NUM> (<NUM> inches).

According to one embodiment, the first block <NUM> has a first length L1 of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), a second length L2 of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), a width W1 of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), a height H of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), or any combination thereof. According to one embodiment the first block <NUM> may have a first length L1 of about <NUM> (<NUM> inches), a second length L2 of about <NUM> (<NUM> inches), a width W1 of about <NUM> (<NUM> inches), and a height H of about <NUM> (<NUM> inches).

According to one embodiment, the first block <NUM> has a first length L1 of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), a second length L2 of between about <NUM> (<NUM> inch) and about <NUM> (<NUM> inches), a width W1 of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), a height H of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), or any combination thereof. According to one embodiment the first block <NUM> may have a first length L1 of about <NUM> (<NUM> inches), a second length L2 of about <NUM> (<NUM> inches), a width W1 of about <NUM> (<NUM> inches), and a height H of about <NUM> (<NUM> inches).

According to one aspect of the disclosure, a kit includes a plurality of hardscaping units <NUM>, the plurality of hardscaping units <NUM> including a first hardscaping unit, a second hardscaping unit, and a third hardscaping unit. The first hardscaping unit may include a first block <NUM> having a first length L1 of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), the second hardscaping unit may include a first block <NUM> having a first length L1 of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), and the third hardscaping unit may include a first block <NUM> having a first length L1 of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches). According to one embodiment, the first blocks <NUM> of each of the first, second, and third hardscaping units may have equal widths W, equal heights H, or both.

The first block <NUM> may include a recess <NUM>. The recess <NUM> may extend through both the top surface <NUM> and the bottom surface <NUM> such that the recess <NUM> extends through an entirety of the height H of the first block <NUM>. Alternatively, the recess <NUM> may extend only through a portion of the height H of the first block <NUM>. The recess <NUM> may be configured as a handhold for the first block <NUM>, as a gap sized to reduce the amount of material needed to make the first block <NUM>, or both. The first block <NUM> may include a plurality of recesses <NUM>. Multiple ones of the plurality of recesses <NUM> may be defined by the same surfaces of the first block <NUM>.

As shown in the illustrated embodiment, the first block <NUM> may include a first recess 116a defined by the first side surface <NUM>, the top surface <NUM> and the bottom surface <NUM>. The first block <NUM> may include a second recess 116b defined by the second side surface <NUM>, the top surface <NUM> and the bottom surface <NUM>. As shown in the illustrated embodiment, the first recess 116a and the second recess 116b may be substantially identical in size and shape. Alternatively, different ones of the recesses <NUM> may have different sizes, different shapes, or both.

The recess <NUM> may be formed in a variety of different shapes, such as, but not limited to, elliptical, rectangular, triangular, dovetail, geometric, and non-geometric. In further aspects, the recess <NUM> may be configured to receive a material, such as, but not limited to, cement, soil, sand, mulch, planting material, or a combination of the above, or other suitable material used in the field of landscaping or hardscaping.

According to one embodiment, the first block <NUM> may include a notch <NUM>. The notch <NUM> may be positioned on one or more surfaces of the first block <NUM>. As shown in the illustrated embodiment, the first block <NUM> may include one or more of the notches <NUM> defined at least partially by the front surface <NUM>. The notch <NUM> may further be defined by additional surfaces of the first block <NUM>. For example, the notch <NUM> may be further defined by the top surface <NUM>, the bottom surface <NUM>, or both. Thus the notch <NUM> may extend through a portion of the height H of the first block <NUM>, up to an entirety of the height H of the first block <NUM>.

The notch <NUM> may define one of a variety of shapes and dimensions. The notch <NUM> may have a cross-section shape, as viewed in the second direction D2, that is triangular, trapezoidal, or other geometric and non-geometric shapes. According to the invention, the notch <NUM> extends into the front surface <NUM> in a direction opposite the first direction D1 and terminates at a base surface 114a. The notch <NUM> defines a cross-sectional shape wherein an opening of the notch <NUM> in the front surface <NUM> defines a length measured in the third direction D3 that is greater than a length of the base surface 114a measured in the third direction D3.

The notch <NUM> may be constructed to have various widths, lengths, and depths. The notch <NUM> includes side walls 114b. The side walls 114b may be not straight, non-parallel, or both. The first block <NUM> may include a first notch and a second notch. The first and second notches may be identical, or they may differ in at least one of size and cross-sectional shape. According to the claimed invention, the first block <NUM> includes one, two, three, four, or five notches defined at least partially by the front surface <NUM>. More specifically, the first block <NUM> may include <NUM> or <NUM> notches defined at least partially by the front surface <NUM>.

The notches <NUM> may be evenly spaced such that the each of the notches <NUM> defined at least partially by the front surface <NUM> is equidistant from adjacent ones of the notches <NUM> defined at least partially by the front surface <NUM>. A first one of the notches <NUM> may be spaced a length from one end of the front surface <NUM> that is equal to a length a second one of the notches <NUM> is spaced from another end of the front surface <NUM>. According to one embodiment, the first length LI of the first block <NUM> may be about <NUM> (<NUM> inches), a first one of the notches <NUM> may be spaced from an intersection of the front surface I <NUM> and the first side surface <NUM> by about <NUM> (<NUM> inches), and a second one of the notches <NUM> may be spaced from an intersection of the front surface <NUM> and the second side surface <NUM> by about <NUM> (<NUM> inches). The first block <NUM> may further include a third one of the notches <NUM> that is spaced about <NUM> (<NUM> inches) from the first one of the notches <NUM> and spaced about <NUM> (<NUM> inches) from the second one of the notches <NUM>.

According to another embodiment, the first length L1 of the first block <NUM> may be about <NUM> (<NUM> inches), a first one of the notches <NUM> may be spaced from an intersection of the front surface <NUM> and the first side surface <NUM> by about <NUM> (<NUM> inches), and a second one of the notches <NUM> may be spaced from an intersection of the front surface <NUM> and the second side surface <NUM> by about <NUM> (<NUM> inches). According to another embodiment, the first length L1 of the first block <NUM> may be about <NUM> (<NUM> inches), a first one of the notches <NUM> may be spaced from an intersection of the front surface <NUM> and the first side surface <NUM> by about <NUM> (<NUM> inches), and a second one of the notches <NUM> may be spaced from an intersection of the front surface <NUM> and the second side surface <NUM> by about <NUM> (<NUM> inches).

The notch <NUM> has a width W2 measured from the front surface <NUM> to the base surface 114a in the first direction D1. The notch <NUM> further has a length L3 measured from an intersection of the front surface <NUM> and one of the side walls 114b to an intersection of the front surface and the other of the side walls 114b in the third direction D3. According to one embodiment, the width W2 of the notch is between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), for example about <NUM> (<NUM> inches), the length L3 of the notch <NUM> is between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches), for example about <NUM> (<NUM> inches), or both.

The first block <NUM> is formed from a first material that includes dry cast concrete. According to the claimed invention the first material includes water and cement, and a water to cement ratio of between about <NUM> to about <NUM>. The first material may have zero slump.

The first block <NUM> is formed by placing the first material into a first mold. The first mold is configured to shape the first material into the desired shape of the first block <NUM>. When the first material takes the desired shape, the first material, having formed the first block <NUM>, is removed from the first mold. The first block <NUM> may be cured to affect properties of the first block <NUM>. For example, the first block <NUM> may be heated for a duration of time to increase robustness.

Referring to <FIG>, the hardscaping unit <NUM> also includes the second block <NUM>. The second block is formed from a second material <NUM>. The second material <NUM> includes wet cast concrete. According to the claimed invention the second material <NUM> includes water and cement, and a water to cement ratio of about <NUM> or higher. Thus, according to the claimed invention, the second block <NUM> includes the second material <NUM> which has a greater water to cement ratio than that of the first material of the first block <NUM>. The second material <NUM> may be configured to change from a first constitution to a second constitution. In the first constitution the second material <NUM> is unsolidified, or in a more liquid state, and in the second constitution the second material <NUM> is solidified, or in a more solid state.

The second block <NUM> may have a face surface <NUM> and a contact surface <NUM>. The contact surface <NUM> may be substantially planar and the face surface <NUM> may be opposite the contact surface <NUM>. The face surface <NUM> of the second block <NUM> may include aesthetic features, such as, but not limited to, textures, designs, carvings, cutouts, or other features, for example features that mimic the appearance of natural stone. The face surface <NUM> may be constructed to resemble aspects appearing in nature, such as, but not limited to, stone, gravel, or planting material. In some aspects, the face surface may include features such as paint, clay, siding material, cement, plaster, or other building materials desirable in the field of landscaping or hardscaping.

The second block may include one or more protrusions <NUM>. The protrusion <NUM> may define a shape that corresponds to the shape of the notch <NUM> of the first block <NUM>. As shown the protrusion <NUM> may extend from the contact surface <NUM>.

The second block <NUM> may be formed by placing the second material <NUM> into a second mold <NUM>. The second mold <NUM> shapes the second material <NUM> into the desired shape of the second block <NUM>. In one embodiment the second material <NUM> is removed from the second mold <NUM> after the second block <NUM> is shaped. The second block <NUM> may then be fixedly attached to the first block <NUM>. In other aspects, the second material <NUM> is not removed from the second mold <NUM> until after the first block <NUM> is fixedly attached to the second material <NUM>, which has formed the second block <NUM>.

According to one embodiment, after the first block <NUM> is fixedly attached to the second block <NUM> the hardscaping unit <NUM> may be devoid of any portion of the first block <NUM> being nested between portions of the second block <NUM> with respect to the first direction D1, the hardscaping unit <NUM> may be devoid of any portion of the second block <NUM> being nested between portions of the first block <NUM> with respect to the first direction D <NUM>, or both. As shown in the illustrated embodiment of <FIG>, the hardscaping unit <NUM> defines no line that can be drawn in the first direction Dl and that passes through one of the first block <NUM> and the second block <NUM>, then passes through the other of the first block <NUM> and the second block <NUM>, and then passes through the one of the first block <NUM> and the second block <NUM> again.

Referring to <FIG>, after the first block <NUM> and the second block <NUM> are fixedly attached to one another to form the hardscaping unit <NUM>, the hardscaping unit <NUM> may include a first portion, a second portion, and a third portion. The first portion <NUM> includes the first material, but does not include the second material <NUM>. The second portion <NUM> includes the second material <NUM>, but does not include the first material. The third portion <NUM> is positioned between the first portion <NUM> and the second portion <NUM> with respect to the first direction D1, and the third portion <NUM> includes both the first material and the second material <NUM>.

Referring to <FIG>, the hardscaping unit <NUM> may be configured for use as a corner unit <NUM> in the wall <NUM>. The first block <NUM> of the corner unit <NUM> may include two or more surfaces, for example the front surface <NUM> and the first side surface <NUM>, in contact with the second block <NUM>.

According to one aspect of the disclosure, the front surface <NUM> and the first side surface <NUM> may each simultaneously contact the second material <NUM> when the second material <NUM> is in the second mold <NUM>. The first block <NUM> may be impacted, for example in a direction normal to the front surface <NUM>, in a direction normal to the first side surface <NUM>, or both. The second material <NUM> may be cured and then removed from the second mold <NUM>. Alternatively, the front surface <NUM> and the first side surface <NUM> may each separately be contacted with the second material <NUM> while the second material <NUM> is in the second mold <NUM>.

As shown in the illustrative embodiment the front surface <NUM> and the first side surface <NUM> are substantially perpendicular to each other and each contact the second block <NUM>. Each of the front surface <NUM> and the first side surface <NUM> includes at least one of the notches <NUM> configured to engage with corresponding protrusions <NUM> of the second block <NUM>. According to other embodiments, the first block <NUM> of the corner unit <NUM> may include more than two surfaces that contact the second block <NUM> of the corner unit <NUM>. Although the front surface <NUM> and the first side surface <NUM> are perpendicular to each other in the illustrated embodiment, the surfaces of the first block <NUM> that contact the second block <NUM> may be at a non-perpendicular angle relative to one another.

Referring to <FIG>, the first block <NUM> of hardscaping unit <NUM> may contact the second material <NUM> while the second material <NUM> is in second mold <NUM>. As shown in the illustrative embodiment of <FIG>, the first block <NUM> may be positioned in the second mold <NUM> such that the front surface <NUM> and the first side surface <NUM> simultaneously contact the second material <NUM> within the second mold <NUM>. In some embodiments, the first block <NUM> may be positioned on top of second material <NUM> such that the first block <NUM> is in contact with second material <NUM> at least partly due to the force of gravity. According to one aspect of the disclosure, a force, for example an impact force, may be applied to one or more surfaces of the first block <NUM> while the first block <NUM> is in contact with the second material <NUM>. For example, a force may be applied to a surface of the first block <NUM> opposite the front surface <NUM>, a surface of the first block <NUM> opposite the first side surface <NUM>, or both.

Referring to <FIG>, a method of assembling the hardscaping unit <NUM> includes fixedly attaching the first block <NUM> to the second block <NUM> using one or more the steps described herein. According to the claimed invention, the first material is placed in the first mold, and the first material is then transitioned from a first state to a second state, the second state being more solid than the first state, and in the second state the first material forms the first block <NUM>. The first block <NUM> is then removed from the first mold. The second material <NUM> is placed in the second mold <NUM>. After removing the first block <NUM> from the first mold, at least one surface of the first block <NUM>, for example the front surface <NUM>, is contacted with the second material <NUM> while the second material <NUM> is in the second mold <NUM>. Contact between the first block <NUM> and the second material <NUM> is maintained while transitioning the second material <NUM> from a third state to a fourth state, wherein the fourth state is more solid than the third state, and when in the fourth state the second material <NUM> forms the second block <NUM>, which is fixedly attached to the first block <NUM>. The fixedly attached second block <NUM> is removed from the second mold <NUM>.

The first block <NUM> may be impacted with a force in one or more directions while the first block <NUM> is in contact with the second material <NUM>, which is in the second mold <NUM>. The one or more directions may include a direction substantially perpendicular to the surface of the first block <NUM> that contacts the second material <NUM>.

Multiple surfaces of the first block <NUM> may contact the second material <NUM> simultaneously, for example the front surface <NUM> and the first side surface <NUM>. The first block may be impacted in multiple directions. The first block <NUM> may be impacted in one direction that is substantially perpendicular to one of the contact surfaces, for example the front surface <NUM>, and in another direction that is substantially perpendicular to another of the contact surfaces, for example the first side surface <NUM>.

Impacting the first block <NUM> in one or more directions while at least one surface of the first block <NUM> contacts the second material <NUM> may force a portion of the second material <NUM> into the notches <NUM> of the contact surface of the first block <NUM> thereby resulting in a stronger attachment between the first block <NUM> and the second block <NUM>. Impacting the first block <NUM> may drive the second material <NUM> into contact with the base surface 114a, one or more of the side walls 114b, or both the base surface 114a and one or more of the side walls 114b.

While the first block <NUM> is in contact with the second material <NUM>, a portion of the second material <NUM> may penetrate the surface of the first block <NUM> that is in contact with the second material <NUM>. The contact surface, for example the front surface <NUM> may include one or more cavities, such as, but not limited to, cracks, gaps, pores, orifices, and other openings or recesses that are configured to allow passage of a portion of the second material <NUM> through the contact surface and into the first block <NUM>.

Movement of the portion of the second material <NUM> through the contact surface and into the first block <NUM> may be facilitated by the selection of the first and second materials. According to the claimed invention, use of a dry cast concrete for the first material and a wet cast concrete for the second material <NUM> results in movement of the second material <NUM> into the first block <NUM>. The lower moisture content of the first block <NUM> draws in the higher moisture content material of the second material. The resulting hardscaping unit <NUM> assembled using a method involving one or more of the steps described herein results in a hardscaping unit <NUM> that is less likely to break along the line of contact between the first block <NUM> and the second block <NUM>, for example compared to a hardscaping unit that includes two blocks attached through other methods.

As shown in the illustrative embodiment, the second material <NUM> may form two protrusions <NUM> that engage with two notches <NUM> on the front surface <NUM> of the first block <NUM>. Such an engagement may help to fixedly attach the first block <NUM> to the second block <NUM> to form the hardscaping unit <NUM> and to maintain the fixed attachment during transportation, use, and/or further manufacturing of the hardscaping unit <NUM>.

In addition to any of the steps described above, an adhesive may be applied to one or both of the first block <NUM> and the second block <NUM> to fixedly attach the first block <NUM> and the second block <NUM>. The adhesive may be applied to a contacting surface of the first block, for example the front surface <NUM>, to a contacting surface of the second block, or to contacting surfaces of both the first block <NUM> and the second block <NUM>. In some aspects, multiple adhesives may be applied to either or both of the first block <NUM> and the second block <NUM>. Additional chemical bonding agents may be applied to one or more of the contacting surfaces. In some aspects, a bonding agent may alter the contact surface of the first block <NUM> or the contact surface of the second block <NUM> so as to improve the attachment of the first block <NUM> to the second block <NUM>. A bonding agent may be applied to either or both of the first block <NUM> and the second block <NUM> to facilitate movement of the second material <NUM> from the second block <NUM> into the first block <NUM>.

The first block <NUM> and the second block <NUM> are fixedly attached to one another after both the first material and the second material <NUM> are in a solid state. In some aspects, the second block <NUM> may be altered before being fixedly attached to the first block <NUM>. For example, the second block <NUM> may have one or more of its surfaces smoothened to increase the surface area configured to contact the first block <NUM>.

The first block <NUM> and the second block <NUM> may be fixedly attached to one another via a combination of the attachment methods described herein. In some aspects, multiple ones of the second block <NUM> may be attached to a single one of the first block <NUM> to form the hardscaping unit <NUM>. Alternatively, multiple first blocks <NUM> may be attached to a single second block <NUM> to form the hardscaping unit <NUM>.

According to the claimed invention, the method of manufacturing the hardscaping unit <NUM> include the steps of manufacturing the first block <NUM>, contacting the first block <NUM> with the second material <NUM>, and forming the second block <NUM> out of the second material <NUM> while the second material <NUM> is in contact with the first block <NUM>.

Aspects of manufacturing the first block <NUM> include placing a first material into a first mold. The first material is configured to enter and take the shape of the first mold. After the first material has taken the shape of the first mold, thus forming the first block <NUM>, the first block <NUM> is removed from the first mold. The first block <NUM> may then be further cured to improve structural or chemical properties. The curing step may include drying the first block <NUM>. The curing step may additionally, or alternatively, include heating the first block <NUM>. In some aspects, the first block <NUM> may be further manufactured by treating one or more surfaces of the first block <NUM>, smoothing one or more surfaces of the first block <NUM>, applying a chemical substance, for example an adhesive, a bonding agent, a sealant, or another chemical substance, to one or more surfaces of the first block, fragmenting the first block <NUM> into smaller portions, or any combination thereof.

Aspects of manufacturing the second block <NUM> include placing the second material <NUM> into the second mold <NUM>. The second material <NUM> is configured to enter and take the shape of the second mold <NUM>. After the second material <NUM> has taken the desired shape, thus forming the second block <NUM>, the second block <NUM> may be removed from the second mold <NUM>. The second block <NUM> may be further cured or manufactured by using any of or any combination of the steps described above in reference to the first block <NUM>.

The hardscaping unit <NUM> described herein may result in a stronger attachment between the first block <NUM> and the second block <NUM> compared to hardscaping units assembled using methods other than those described herein. According to one embodiment, the second block <NUM> may be less likely to become detached from the first block <NUM> without plastically deforming (or breaking) the hardscaping unit <NUM>. In addition to improving durability of the hardscaping unit <NUM>, a stronger attachment between the first block <NUM> and the second block <NUM> may result in more efficient packaging, transportation, and installation of the hardscaping units <NUM>.

Hardscaping units assembled using methods other than those described herein may result in a finished product with a gap between first and second portions of the finished product. The hardscaping unit <NUM> assembled as described herein on the other hand may result in a relatively small gap or no gap between the first block <NUM> and the second block <NUM>. The smaller gap, or the lack of a gap, lowers the chance of debris or water entering the gap between the first block <NUM> and the second block <NUM>. Less debris between the first block <NUM> and the second block <NUM> may lower the chance of seeds or other organic material filling the gap, growing, and expanding, thus applying stresses on the contacting surfaces of the first block <NUM> and the second block <NUM>, potentially leading to detachment or fracturing of one or more of the first block <NUM> and the second block <NUM>. The reduction or elimination of a gap between the first block <NUM> and the second block <NUM> also reduces the chance of an edge of one of the hardscaping units <NUM> catching on an edge of the gap of another of the hardscaping units <NUM>, thus increasing the efficiency with which the wall <NUM> can be built.

There also exist benefits of manufacturing the hardscaping unit <NUM> using the methods described herein. According to the claimed invention the at least one contacting surface <NUM> of the first block is maintained in contact with the second material <NUM> while transitioning the second material <NUM> from a third state to a fourth state, wherein the fourth state is more solid than the third state, and when in the fourth state the second material <NUM> forms a second block <NUM> that is secured relative to the first block <NUM>. The second block is then formed while being in contact with the first block <NUM>. This method of manufacturing the hardscaping unit <NUM> requires less time to manufacture than using other methods of manufacture, such as forming the first block <NUM> and the second block <NUM> separately and then attaching the formed first block <NUM> and the formed second block <NUM> to each other once both are in a solidified state.

Additional manufacturing time may be saved because the hardscaping unit <NUM> manufactured according to the methods described herein allows for the option of curing the first block <NUM> and the second block <NUM> together, rather than curing each of the first block <NUM> and the second block <NUM> individually and then curing the fixedly attached first and second blocks <NUM>, <NUM> again. Many, if not all, of the advantages listed herein may reduce costs associated with manufacturing hardscaping units.

It will be appreciated that the foregoing description provides examples of the disclosed hardscaping unit <NUM> and methods of manufacturing and assembling the hardscaping unit <NUM>. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the disclosure entirely unless otherwise indicated.

Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range including the stated ends of the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.

Claim 1:
A method of assembling a hardscaping unit (<NUM>), the method comprising the steps of:
placing a first material into a first mold;
while the first material is in the first mold, transitioning the first material from a first state to a second state, wherein the second state is more solid than the first state, and when in the second state the first material forms a first block (<NUM>), wherein the first block (<NUM>) includes at least one contacting surface (<NUM>);
removing the first block (<NUM>) from the first mold;
placing a second material (<NUM>) into a second mold (<NUM>);
contacting the at least one contacting surface (<NUM>) of the first block (<NUM>) with the second material (<NUM>), while the second material (<NUM>) is in the second mold (<NUM>);
after the contacting step, maintaining contact of the at least one contacting surface (<NUM>) of the first block with the second material (<NUM>) while transitioning the second material (<NUM>) from a third state to a fourth state, wherein the fourth state is more solid than the third state, and when in the fourth state the second material (<NUM>) forms a second block (<NUM>) that is secured relative to the first block (<NUM>);
after the maintaining step, removing the second block (<NUM>) from the second mold (<NUM>);
characterized in that the first material includes a dry cast concrete, the first material having a water to cement ratio of between about <NUM> to about <NUM>, the second material includes a wet cast concrete, the second material having a water to cement ratio of about <NUM> or higher.