AU2008202153A1 - Retaining wall block and method of manufacture - Google Patents

Description

(followed by page 1a) Regulation 3.2 AUSTRALIA PATENTS ACT, 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT ORIGINAL Name of Applicant: SHAW TECHNOLOGIES, INC. Actual Inventor: SHAW, Kenneth L. A address for service in A J PARK, Level 11, 60 Marcus Clarke Street, Canberra ACT Australia: 2601, Australia Invention Title: RETAINING WALL BLOCK AND METHOD OF MANUFACTURE The following statement is a full description of this invention, including the best method of performing it known to us. 141052/1468167_1. )OC Patent Application Docket No. 46950-PO16US RETAINING WALL BLOCK AND METHOD OF MANUFACTURE CROSS REFERENCE IS RELATED APPLICATIONS [001] The present application claims priority to, and incorporates by reference the entirety of U.S. Provisional Application Serial Number 61/021956 filed January 18, 2008. BACKGROUND OF THE INVENTION Field of the Invention [002] The present invention relates to retaining walls, and more particularly, but not by way of limitation, to retaining wall blocks and methods of manufacture. The retaining wall blocks are of selectively reduced weight and may be used with optional, select stabilizing elements and methods therewith and fabricated from concrete or other materials. History of Related Art [003] Retaining walls of various designs have been used in general construction, and particularly in landscaping for many years. The design of, the weight in, and the materials used for, such retaining walls have varied over time. Retaining walls are typically used to support or retain soil or the like in place, but also may be used to enhance the appearance of a surrounding area. Such walls typically stand on a ground region and retain there behind an earthen section or other fill material, which earthen section would otherwise form a natural slope in place of the retaining wall. Such retaining walls are typically vertical or at a slight angle. A generally vertical retaining wall may begin to deform as a mass of the earth retained behind it presses against it. A wall must resist this tendency. In addition, designers of retaining walls are constantly striving to construct more economical and aesthetically pleasing retaining walls having greater strength and less weight. 1IA 5206472v.2 46950/PO16US Patent Application Docket No. 46950-PO16US [004] One of the most popular, and aesthetically pleasing forms of retaining wall construction involves the use of manually positionable individual blocks. The blocks may be stacked on top of the other to form a pattern on an outside face of the retaining wall. It can be very time consuming and tedious aligning numerous blocks to form the proper pattern in the retaining wall. Heavier retaining wall blocks are typically harder to handle than lighter weight blocks. In addition, a retaining wall may have one or more curved portions. The very design of many retaining wall blocks to assist in maintaining stability may be counter to the formation of a curved wall portion. In addition, certain retaining wall anchors are very cumbersome and laborious to install. Wall anchors include one end which is placed in a void of a retaining wall block. The block is then filled with concrete or similar substance in order to secure the anchor attachment. The concrete must then dry or settle before the assembly of the retaining wall can continue. A block for retaining walls and a retaining wall system is needed which provides enhanced structural support for individual blocks in both curved and linear wall portions, and is simple to use as well as simple and inexpensive to manufacture. [005] Related art references discussing subject matter bearing some relations to matters discussed herein include U.S. Patent Number 5,941,042 to Dueck (Dueck), U.S. Patent Number Re. 37,278 to Forsberg (Forsberg), U.S. Patent Number 5,704,183 to Woolford (Woolford), U.S. Patent Number 4,964,761 to Rossi (Rossi), U.S. Patent Number 5,214,898 to Beretta (Beretta), U.S. Patent Number 5,294,216 to Sievert (Seivert), U.S. Patent Number 5,711,130 to Shatley (Shatley), U.S. Patent Number 5,484,236 to Gravier (Gravier), German Gebrauschsmuster DE 295 00 694 Ul to Ming Su (Ming Su), U.S. Patent Number 5,865,006 to Dawson (Dawson), U.S. Patent Number 380,560 to Forsberg, U.S. Design Patent Number 384,168 to Stevenson, U.S. Design Patent Number 397,451 to Stevenson, U.S. Patent Number 5,540,525 to Miller (Miller), 2 5206472v.2 46950/P016US Patent Application Docket No. 46950-PO16US U.S. Patent Number 5,800,097 to Martin (Martin), U.S. Patent Number 5,487,623 to Anderson et al (Anderson), U.S. Patent Number 5,881,511 to Keller, Jr. (Keller), U.S. Patent Number 5,524,551 to Scheiwiller (Scheiwiller), U.S. Patent Number 6,260,320 B1 to Di Lorenzo (Di Lorenzo), U.S. Patent Number 5,226,275 to Trahan (Trahan), U.S. Patent Number 4,824,293 to Brown (Brown), U.S. Patent Number 5,522,682 to Eagan (Egan), and U.S. Patent Number 6,176,059B 1 to Cantarano et al (Cantarano). [006] In broad terms, and not to be interpreted as comprehensive, the above patents may be said to disclose the following: Dueck discloses a retaining wall block with downward extending cylindrical knobs. Forsberg discloses pins and pockets for interlocking overlapping blocks. Woolford discloses a masonry block which has a centrally-located and dogbone-shaped, or two centrally-located circular, protrusions aligned with an opposing inset (or insets) extending partially into the block. Rossi discloses dry-mounted construction elements for use in a retaining wall with a series of openings within each block. Beretta discloses retraining wall blocks with a cambered front, tapering side walls and an abutment for engagement with an adjacent lower block. Sievert discloses a solid composite masonry retaining wall block with a flange extending down from the block back surface past the height of the block. Shatley discloses a retaining wall building block with rearward and forward aligning elements extending downward, holes extend through the blocks and pins for interlocking them together. Graiver discloses retaining wall blocks with an upward lateral extending front lip and a laterally extending recess. Dawson discloses a retaining wall block with a flange extending downward from the block's rear surface. The Forsberg design patent discloses a three faceted broken front face retaining wall block with a rear edge protrusion from the bottom surface of the block. The 384,168 Stevenson design patent discloses a retaining wall block with 2 rear protrusions from the bottom surface of the block. 3 5206472v.2 46950/P01 6US Patent Application Docket No. 46950-POl6US The 397,451 Stevenson design patent discloses a portion of a retaining block wall using the retaining wall blocks of the 384,168 design patent. Miller discloses a groove in the side of a block. Martin discloses an array of projections on the top face of a block that fits into an array of apertures on a bottom fact of a higher block. Anderson discloses vertical rods inserted through holes of the blocks in order to form reinforced columns. Keller discloses block having a dovetail section for fitting together with adjacent blocks. The Scheiwiller discloses blocks having holes for attaching with other blocks by filling the holes with concrete. Di Lorenzo discloses wall flanges held together by rods or cables that are held in each adjacent brick. Trahan discloses a block with a lower lip that fits into the block below it. Brown discloses a wall using a tieback to connect to a lower member. Egan discloses a modular wall block with rearward abscesses for receiving grid connectors. Cantarano discloses a wall form panel with interlocking protrusions around the edges which make the panel reversibly symmetric. SUMMARY OF THE INVENTION [007] The present invention relates to retaining wall blocks of reduced weight and methods of manufacture. More particularly, one aspect of the present invention includes a retaining wall block and method of manufacture incorporating a recessed mounting surface for reducing weight and/or receiving a stabilizing element facilitating securement of the stabilizing element with an anchoring element, thereby providing additional support and sturdiness to the retaining wall block system. In one embodiment, the recessed mounting surface is contiguous to a hollow central section of the type conventional in certain retaining wall block manufacture. BRIEF DESCRIPTION OF DRAWINGS [008] A more complete understanding of the method and apparatus of the present invention may be obtained by reference to the following Detailed Description when taken in 4 5206472v.2 46950/P01 6US Patent Application Docket No. 46950-Po1 6US conjunction with the accompanying Drawings wherein: [009] FIGs. IA and 1B illustrate two embodiments of an improved retaining wall block in accordance with principles of the present invention; [00101 FIG. 2 is a flow diagram illustrating one embodiment of the manufacture of the wall block of FIGs. 1A and IB; [0011] FIGs. 3A and 3B are diagrammatic schematics of a representative illustration of sections of male and female molds illustrating aspects of the molding of the retaining wall blocks of FIG 1A and IB; [0012] FIG. 4 is a perspective view of a prior art retaining wall assembly as set forth in U.S. Patent 6,464,432 B 1 for reference purposes; and [0013] FIG. 5 is a diagrammatic schematic side elevation of one embodiment of a portion of a retaining wall 300 of the present invention utilizing a plurality of the blocks of FIG. IA and methods in accordance with certain of the principles of the present invention. . DETAILED DESCRIPTION [0014] Various embodiments of the present invention will now be described more fully with reference to the accompanying drawings. The invention may, howeve-, be embodied in many different forms and should not be constructed as limited to the embodiments set forth herein; rather, the embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. [0015] Applicant of the present patent application has discovered that the use of hollow, 5 5206472v.2 46950/PO16US Patent Application Docket No. 46950-PO16US lighter weight retaining wall blocks with a specially formed surface recess is an advantage from both cost and handling standpoints. In certain instances, the retaining wall block must be positioned in a configuration necessitating special attention in the stabilization of the individual retaining wall blocks. The present retaining wall blocks have been particularly configured for both lighter weight, ease of manufacture and receipt of a stabilization bar. [0016] Referring now to figure 1 A and lB in combination, there are shown perspective views of retaining wall blocks constructed in accordance with certain embodiments of the principles of the present invention. It should be noted that the blocks 10 may preferably be stacked into a retaining wall in a position "upside down" to that shown in FIGs. lA and 1B. The blocks 10 will, however, be described in the orientation seen in FIGs. 1A and lB. In that regard, block 10 is formed with a frontal surface 12 and first side surface 14 disposed in spaced relationship from a second side surface 16 connected by a top surface 18 (again, top surface 18 will, in the preferred assembly, be a bottom area as seen in FIG. 5). It may be seen that the top surface 18 includes an upstanding aligning element or region 20 at the rear end of the block 10 and an indentation 22 extending across the top surface 18 of the block. In FIG. I B a large, hollow void 24 is formed herethrough which void 24 may be seen in the prior art blocks of FIG. 4 below. According to exemplary embodiment, the blocks 10 may be formed of, for example, concrete, injection molded plastic, or any other material. [0017] The indentation 22 of FIGs. 1A and lB is provided in an innovative manner for weight reduction, but is also adapted for receipt of an optional stabilization member, in accordance with the principles of the present invention. Indentation 22 reduces weight of the retaining wall block 10 of the present invention and may be formed of varying sizes in order to 6 5206472v.2 46950/PO I6US Patent Application Docket No. 46950-PO16US reduce more weight. Since weight is a significant aspect of the handling, shipping and cost of retaining wall blocks, reduction in weight is an important criteria. One problem in forming weight reducing areas is to maintain the structural integrity of the block while meeting capacity requirements of the molding machines. In the present invention, the shape of the recess 22 is shown with certain sides sloping forming a generally trapezoidal indentation. Other shapes facilitating formation of the block 10 may also be used as described below. As shown herein, the recess 22 has a first, generally orthogonal side wall 30 contiguous angulated side wall 32 which is likewise contiguous on angulated sidewall 34 extended oppositely thereof and finally terminating in an upstanding side wall 36 which is generally orthogonal to top surface 18 and in generally parallel spaced relationship with first side wall 30. It has been found by the inventor of the present application that the utilization of the indentation 22 in the configuration presented with optional hollow region 24 provides a retaining wall block with improved characteristics both in fabrication and handling. As referenced ab6ve, however, other angular shapes facilitating the molding operation are contemplated. The other angular shapes would, in accordance with the present invention have tapered sides facilitating penetration of the molded material such as concrete during the molding operation. [0018] As referenced above, the weight of the retaining wall block is critical in both cost of materials as well as shipping and handling. Techniques to reduce weight and improve efficiency in manufacture are important. The angulated configuration of indentation 22 in the trapezoidal configuration referred to herein, provides an improvement in retaining wall blocks by improving the ease with which such indentations may be made by a molding machine. For example, in the situation where an indentation is generally only rectangular in shape, the amount of pressure necessary to impart such an indentation in a retaining wall block during molding is 7 5206472v,2 46950/PO16US Patent Application Docket No. 46950-PO16US much greater than with the present design having the angulated walls 32 and 34. Because of this design aspect, the capacity of select molding machines may be met with larger block sizes. There is also flexibility in using machines with less capacity for creating an indentation consistent with the present invention as well as increasing the size of the indentation. The presentation of the optional hollow region 24 (shown in FIG. 1 B) contiguous the indentation 22 is of similar advantage (though hollow central areas are known; see U.S. Patent No. US. 6,464,432, assigned to the assignee of the present invention) in allowing the removal of mass which contributes to the weight of the block. It should further be noted that the relative sizes of indentation 22 and any optional hollow region 24 may vary in accordance with the principles of the present invention. [0019] It may thus be seen from FIGs. 1A and 1B that the retaining wall block of the present invention provides not only reduced weight (an advantage for shipping and handling) but also an indentation design featuring angulated walls 32 and 34 which maximize the capacity of molding machines selected to mold the block 10 of the present invention. Other angulation designs are, of course, contemplated by the inventors of the present invention. [0020] Referring now to FIG. 2, there is shown a flow diagram illustrating one embodiment of the manufacture of one embodiment of the present invention. In step 80, a female form or mold 180 is formed having a capacity for containing the necessary amount of material such as, for example, concrete, injection molded plastic, or other such material for the formation of the retaining wall block 10 of the present invention and defining the outside configuration thereof. In step 82, a male form or mold 182A or 182B is provided having a tapered male portion 183 extending thereacross adapted for forming the indentation as shown in 8 5 2 06472v.2 469501P016US Patent Application Docket No. 46950-PO16US FIGs. lA and lB across the top surface 18 of the block 10 formed therewith. In step 84 the appropriate amount of material such as, for example, concrete, is placed in the female mold 180 and in step 86 the male mold 182A or 182B is inserted therein to form the block 10 with embeded indentation 22 thereacross. In step 88 the male mold 182A or 182B is removed and in step 90 the molding and curing process is completed and a retaining wall block 10 having an indentation 22 as shown in FIG. lA is provided. As shown in FIGs. 3A and 3B the mold may include a form adapted to form a central void therethrough and in contiguous engagement with the indentation as further shown in FIG. IB. As referenced above, materials other than concrete are contemplated in the present invention. [0021] Referring now to FIGs. 3A and 3B there are shown diagrammatic schematics of portions of male and female form members illustrating the fabrication of the indentation in the block 10 of FIGs. 1A and lB. In FIG. 3A, the male member 183 is most clearly shown having the tapered configuration necessary forming one embodiment of the indentation 22 shown in FIG. IA. As stated above, various tapered configurations and/or sizes of the male member 183 are possible depending on the size of the indentation 22 desired for both weight and strength considerations. It should further be noted that as both figures 3A and 3B indicate by the cut-off line drawn thereacross, only portions of the male mold are illustrated in this diagrammatic schematic illustration of the forms. In that regard, the upstanding region 20 being in FIG. IA is, for example, required to be formed by a portion of the mold not shown herein and, additionally, the exact shape of the female form 180 may vary and, in particular, but may be seen that the corner region shown in FIG. 1A are not illustrated herein for purposes of simplicity. Likewise, in FIG. 3B, a male member section 183 may be seen to extend out opposite sides of the male member 182B which further includes a central region 182C in a position to form the central void 9 5206472v.2 46950/PO 6Us Patent Application Docket No. 46950-POI 6US 24 illustrated in FIG. 1 B. Again, the size, shape, and other parameters of such a central void 24 may vary and the present drawings are for purposes of illustration only, as variations thereof are contemplated within the spirit and scope of the present invention. [0022] Referring now to the above referenced U.S. Patent number 6,464,432 BI (the '432 patent) there is shown a retaining wall block with a central section which is hollow. FIG. 5 of the '432 patent is reproduced herein as FIG. 4 for purposes of illustrating both the prior art and one embodiment of stacking of retaining wall blocks into a retaining wall. FIG. 4 is thus a perspective view of a retaining wall 3 utilizing a plurality of blocks I according to the teachings of the '432 patent. [0023] The blocks 1 are stacked one on top of another to form a retaining wall 3. However, as illustrated in FIG. 4, the placement of a block I is centered upon the top of two lower blocks, by staggering the top block one half unit. By staggering the blocks 1, a running bond pattern can be achieved, which provides an appealing design. The extension 11 of an upper block 1 is placed upon the slot 15 of a lower block 1. Since the extension is wider than the slot 15, when the blocks I are stacked, a vertical offset is achieved. This offset increases the overall stability and strength of the walls. Additionally, the extensions and slots 15 provides an interlocking means between the blocks, allowing a greater strength in the retaining wall 3. A geo-grid 19 may also be placed between each layer of blocks. The geo-grid 19 is commonly used in retaining walls to provide additional support to the retaining wall 3. However, with the addition of the slots 15 and the extensions 11, an increased fictional coefficient is achieved between the geo-grid 10 and the blocks 1, which provides a stronger support for the retaining wall 3. Aggregate may be placed within each void 5 of the blocks 1, again enhancing the overall 10 5206472v.2 46950/PO16US Patent Application Docket No. 46950-PO16US strength of the retaining wall 3. The retaining wall 3 provides both increased strength as well as a pleasing appearance. [0024] Referring now to FIG. 5, there is shown one embodiment of a portion of a retaining wall 300 utilizing a plurality of blocks 10 of FIG. IA. It may be seen that "top surface 18" is actually positioned as a "bottom surface" in this particular installation. As may be seen herein, the retaining wall blocks 10 of FIG. 5 further include the utilization of mesh 301 extending behind the stacked blocks 10 in order to secure the retaining wall 300 in its position relative to earthen formation. FIG. 5 is, however, only illustrative of one method of assembly and mesh 301 may or may not be used. Likewise, the bottom row of blocks 10 must either have the lower alignment element 20 extending from surface 18 removed or a groove across formed in the underlying surface area 303 in order for the lower block 305 to remain level. As may be seen here, the retaining wall blocks 10 of the present invention may be fabricated in virtually identical configurations for a single, retaining wall. Some modification, such as removing element 20 may be required during installation. Likewise the utilization of the stabilizing element and/or mesh 301 extending rearwardly thereof is optional in accordance with then principles of the present invention. [0025] It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. While the method and apparatus shown or described has been characterized as being preferred it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the invention as defined in the following claims. [00261 The term "comprising" as used in this specification means "consisting at least in part of'. When interpreting each statement in this specification that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner. 11

Claims (20)

1. An interlock g retaining wall block, adapted for assembly into a retaining wall system including a plurality of stacked rows of at least a plurality of said blocks, said block comprising: left, right, front and rear body portions, said front and rear body portions of said blocks being connected by said left and right body portions, defining a first surface; a substantially planar second, opposite surface of said block; at least one indentation formed across said first surface, the indentation having at least two angulated side walls facilitating fabrication thereof; and at lease one aligning element extending from said first surface of said block.

2. The interlocking retaining wall block of claim 1, wherein the at least one aligning element extends in generally parallel spaced relationship from the at least one indentation formed across said first surface.

3. The interlocking retaining wall block of claim 1, further comprising a central void formed through said retaining wall block to reduce weight thereof.

4. The interlocking retaining wall block of claim 3, wherein the central void extending through said block is defined by wall portions in generally parallel spaced relationship with the left and right body portions of said block.

5. The interlocking retaining wall block of claim 1, wherein the at least one 12 5206472v.2 46950/P016US Patent Application Docket No. 46950-PO16US indentation comprises first and second wall sections in generally parallel spaced relationship contiguous a bottom surface comprised of angulated walls extending therefrom and extending into said block.

6. The interlocking retaining wall block of claim 5, wherein said first and second wall portions are in generally parallel spaced relationship with said the at least one aligning element extending from said first surface of said block.

7. The interlocking retaining wall block of claim 1, further comprising at least two angulated comer regions between said front and said left and right body portions of said block.

8. The interlocking retaining wall block of claim 1, further comprising said at least one aligning element extending substantially across said first surface along said rear body portion to serve as an alignment element during installation of said block one atop another.

9. The interlocking retaining wall block of claim 1, wherein said block is formed of concrete.

10. The interlocking retaining wall block of claim 1, wherein said block is formed of injection molded plastic.

11. A method of manufacturing an interlocking retaining wall block, adapted for assembly into a retaining wall system including a plurality of stacked rows of at least a plurality of said blocks, said method comprising: forming male and female molds adapted to form left, right, front and rear body portions of a block, said front and rear body portions of said blocks being connected by said left 13 5206472v.2 46950/POI 6US Patent Application Docket No. 46950-PO 1 6US and right body portions, defining a first surface; molding said block with a substantially planar second, opposite surface from said first surface; molding at least one indentation formed across said first surface, the indentation having at least two angulated side walls facilitating fabrication thereof; and molding at least one aligning element extending from said first surface of said block,

12. The method of claim 11, wherein the at least one aligning element extends in generally parallel spaced relationship from the at least one indentation formed across set first surface.

13, The method of claim 11, further comprising forming a central void through said retaining wall block to reduce the weight thereof.

14. The method of claim 13, wherein the central void extends through said block, defined by certain wall portions in generally parallel spaced relationship with the left and right body portions of said block.

15. The method of claim 11, wherein the at least one indentation is formed with first and second wall sections in generally parallel spaced relationship contiguous a bottom surface comprised of angulated walls extending therefrom and extending into said block.

16. The method of claim 15, wherein said first and second wall portions are formed in generally parallel spaced relationship with the at least one aligning element extending from said 14 5206472v.2 46950/1>0I 6US Patent Application Docket No. 46950-POI6US first surface of said block.

17. The method of claim 11, further comprising forming at least two angulated corner regions between said front and said left and right body portions of said block.

18. The method of claim 11, further comprsing forming said at least one aligning element in a position extending substantially across said first surface along said rear body portion to serve as an alignment element during installation of said block one atop another.

19. The method of claim 11, wherein said block is formed of concrete.

20. The method of claim 11, wherein said block is formed of injection molded plastic. 15 5 2 06472v.2 46950/POI 6US