WO2013182832A1

WO2013182832A1 - Interlocking block

Info

Publication number: WO2013182832A1
Application number: PCT/GB2012/000671
Authority: WO
Inventors: David Charles MARDEL; Steven Geoffrey HATT
Original assignee: Mardel David Charles; Hatt Steven Geoffrey
Priority date: 2012-06-06
Filing date: 2012-08-21
Publication date: 2013-12-12
Also published as: GB2502783A; GB201209960D0

Abstract

An interlocking block (1) featuring convex shaped end (2) and concave shaped end (3), consisting of an offset stud or peg (5) on the upper surface which engages variously with channel (7) and slots (8a) and (8b) of the underside of another interlocking block; whereupon a number of blocks repeatedly engage as required forming a plurality of interlocking blocks which create straight or curvilinear horizontal forms and when connected one on top of the other in a stretcher bond style, or laid on their sides, build a traditional vertical, or variable terraced, or staggered offset wall, or combination of both to create an embankment retaining structure, or block paving.

Description

Interlocking block

The present invention relates to an interlocking block. Specifically, the present invention relates to a versatile interlocking block which can be connected together with other identical blocks to build a plurality of blocks which together can form various shapes for use as retaining walls for gardens, embankments and the like. Such an interlocking block will have variations in configuration in final assembly to enable a versatile system to be created which caters for any shape of structure matched against the landscaped contours, terraced or un-terraced of a bank to be retained, whilst also finishing off ends of rows and a top layer forweatherproofing and aesthetics. Interlocking blocks for retaining walls and embankments, for example, are well known in the prior art. Typically a multiplicity of such blocks to build a retaining wall is of complex configuration to ensure adequate interlocking. Most of these methods rely on friction to interlock through lips on the front or rear side of the block that interlock with the block beneath it. Once the area behind the wall to be retained is filled, the dirt or soil pushes the blocks forward causing them to strengthen between the lips. Because such blocks in this situation do not require mortar, they should primarily be used for lower walls because of their inherent lack of stability and strength.

In addition, to function successfully under structural loading such block shapes are complex, will not be able to be terraced without skilled trades and not easily manufactured, regardless of materials, to an economical budget.

It is known that other typical interlocking blocks, for example, are interconnected in a single plane such that they build vertically, which is unsuitable for most applications for retaining walls of any significant height, unless a multiplicity of such blocks, or bricks is laid up against each other forming further layers to bolster the depth of the assembly and therefore resistance for the retained material against collapse.

Furthermore typical interlocking blocks often need the application of skilled trades to facilitate accurate build using mortar or cement to secure the blocks together if building a high wall. In other instances where retaining walls are a structural necessity interlocking blocks are often unsightly and not versatile enough to provide a variety of design configurations to meet the demands and expectations of the modern consumer in either domestic, commercial, or contract marketplaces whilst still offering structural integrity for any height of embankment or retaining wall.

It is an aim of the present invention to overcome or at least mitigate at least one of the above problems and shortcomings.

According to a first aspect of the present invention there is provided an interlocking block,

the interlocking block possibly being connected through a plurality of dry means with a multiplicity of identical blocks,

the interlocking block utilising a keying, or locating method for unskilled labour to line up other blocks to accurately follow the radius of contour of a wall, or embankment to be retained,

the multiplicity of identical blocks forming an assembly of any size or of any contour, wherein the assembly supports any height of embankment to be retained, terraced or un-terraced,

whereby the resulting retaining wall assembly offers a measurable level of structural integrity.

In a preferred embodiment, an interlocking block features a concave radius and a convex radius at opposite ends of typically a block of longer length than width. The radii at opposite ends may offer a nesting and lining up facility for each block as it is built upon another in a horizontal assembly giving the opportunity of providing any radius of build of a multiplicity of blocks which follows and dads any shape of wall to be retained.

In an alternative embodiment possibly from the concave end is formed a protruding male tongue, or mortice which typically follows the radius of that end. Similarly at the other end there may be formed a female groove within the convex end. Such tongue and groove provision without and within each end provides further opportunity for secure location of a multiplicity of interlocking blocks horizontally without compromising the attribute of following the straight or curvilinear shape of a retaining wall. Such mortice and tenon-style connection, in addition to concave and convex nesting is applicable to the interlocking block which features a continuous channel running underneath to locate a stud or peg anywhere along its length.

Therefore in building one block above the other possibly the aforementioned shaped channel formed underneath each block allows a matching stud or peg, preferably situated on the top surface of every block, to interconnect with the shaped channel which is located underneath another block to form either a vertical or terraced build; such vertical build providing a dry assembly of blocks interlocking vertically and horizontally, exhibiting similar strength to the traditional mortar laid brick wall assembly; such terraced build creating a stepped, or staggered assembly which matches the angles and contours of the wall, or embankment to be retained.

To facilitate quick recognition by a builder of the contour shape decided upon in the horizontal mode when viewed from above, location indicators, or markers can be provided preferably on the top surface of both the convex and concave ends of an interlocking block; such markers formed in relief, indented, or printed, or marked in some way in or on, a typical interlocking block offering quick, accurate linking into a planned shape, either straight or curved, or a combination of both, of a plurality of blocks without recourse to measuring. According to a second aspect of the present invention in an alternative embodiment the channel underneath an interlocking block may feature a number of semi-circular cut-outs which friction fit over the aforementioned stud or peg on the top surface of another interlocking block to form an off-set terraced configuration when a plurality of the same are assembled.

According to another aspect of the present invention the convex and concave shaped comers of an interlocking block are truncated to enable each block to nest into each other when laid end to end on their sides. Such end to end connection is in a straight line and when a plurality of blocks is laid on the ground in all four directions the resulting assembly forms block paving. An example interlocking block in accordance with aspects of the present invention will now be described with reference to the accompanying drawings, in which.

Figure 1 is an orthographic third angle projection of an interlocking block in accordance with aspects of the present invention.

Figure 2 is a perspective view of a single row of a contoured multiplicity of interlocking blocks in accordance with aspects of the present invention.

Figures 3a and 3b are perspective views of a multiplicity of interlocking blocks assembled in a terraced straight and contoured configuration in accordance with aspects of the present invention.

Figure 4 is a perspective view of a multiplicity of interlocking blocks assembled in a vertical configuration in accordance with aspects of the present invention.

Figure 5 is a top perspective view of an alternative embodiment showing concavity configurations in accordance with aspects of the present invention.

Figure 6 is a top perspective view of an alternative embodiment showing convexity configurations in accordance with aspects of the present invention.

Figure 7 is a top perspective view of an alternative embodiment depicting a capping stone in accordance with aspects of the present invention.

Figure 8 is an underneath perspective view of an alternative embodiment depicting a capping stone with location slots and cut-outs which facilitate terrace and vertical build respectively in accordance with aspects of the present invention.

Figure 9 is a side perspective view of a capping stone in accordance with aspects of the present invention. Figure 10 is an underneath perspective view of an alternative embodiment depicting a half-capping stone for vertical build only in accordance with aspects of the present invention.

Figure 1 1 is an underneath view of an alternative embodiment depicting ari additional slot for stacking in accordance with aspects of the present invention.

Figure 12 is a side perspective view of an interlocking block depicting tapered convexity at one end and tapered concavity at the other end in accordance with aspects of the present invention.

Figure 13 is an orthographic third angle projection of an alternative embodiment in accordance with aspects of the present invention.

Figure 1 is a sectional plan view of two layers of a plurality of interlocking blocks depicting a curvilinear shape when assembled to a pre-planned contour in accordance with aspects of the present invention.

Figure 15 depicts three views of the underside of an interlocking block showing three different positions of the location peg.

Figures 16a and 16b depict two different views of an alternative embodiment of interlocking blocks laid on their sides. Figures 17a and 17b depict two perspective views of an alternative embodiment of a plurality of interlocking blocks laid on their sides in order to form paving.

Referring to figure 1 interlocking block 1 is shown with a concave end 2 and a convex end 3, both preferably radiused. Peg 5 is sited possibly offset on either side from the longitudinal centreline linking the two aforementioned ends. The height of peg 5 from the top surface is preferably but not exclusively limited to one quarter of the width of interlocking block 1 as shown by dotted lines in side view 6, which also depicts in dotted lines channel 7 of the same depth as peg 5, running longitudinally down the length of interlocking block 1. Two cut-outs 8 of the same depth as channel 7 and of sufficient diameter to friction-fit peg 5, are cut-out possibly along their centrelines, forming preferably two semi-circles. Location marks 9 can be a ayed and aligned around both convex and concave ends, 2 and 3 in order to line up accurately adjacent interlocking blocks during their assembly to match the contours of a wall to be bolstered and retained. Blending curve 10 is sufficient to prevent snagging of interlocking blocks against each other should they be positioned at an acute angle approaching ninety degrees.

In figure 2 a plurality of interlocking blocks is placed together in a typical aaay to form a curvature of assembled blocks achieved through lining up positional location marker 9 with the matching positional location marker 9 on an adjacent block at a consistent point on the convex and concave perimeters of each block in order to create a desired curvilinear shape. Once a base layer of interlocking blocks has been laid and direction of travel decided, figure 3a shows the addition of five more assembled layers in a stretcher bond style configuration, in this instance terraced, or staggered whereby underneath cut-out 8, featured in figure 1 , is located onto peg 5. The concave and convex ends of each block ensure that a plurality of blocks is prevented from sideways shift in a dry friction-fit. Figure 3b depicts the same terraced configuration assembled to form a staggered wall.

In figure 4 a plurality of assembled interlocking blocks is demonstrated in a vertical stretcher bond style vertical wall configuration, whereby peg 5 engages along the length of unsighted, central channel 7, in a block above, instead of engaging in unsighted offset cutout 8, both depicted in figure 1. In figure 5 an alternative embodiment of interlocking block is shown featuring a radial mortise- style raised tongue 12 running inside the concave end typically in parallel with the concavity.

Such radial tongue can run the entire width of an interlocking block or through part of it in a mortise style. Preferably the tongue is tapered from the outside in. In a preferred embodiment channel 7 is shown as a continuous slot. Such a slot, which acts as a 'float' for location peg 5, can be blind at either end or at both ends, or blind at one end and continuous at the other. In a preferred embodiment an array of three location markers 9 are equi-spaced at 45 degrees around the concave end with a single location marker at the convex end. Such markers act as quick recognition to a builder for lining up each block against another one in accordance with an agreed building plan. The shape of the mortise -style protrusion is preferably tapered from the base to the top edge to facilitate easy line up and connection into the tenon-style slot 11 in figure 6. Referring to figure 6 an alternative embodiment of the other end of a typical interlocking block is depicted featuring a tenon-style slot 11, preferably running along part of the radius of the curvilinear face at the convex end. On assembly such tenon-style slot, or groove, is fitted over a mortise-style tongue in an adjacent interlocking block.

In figure 7 in an alternative embodiment a method of finishing off the top layer of an assembly of interlocking blocks which may form a wall is shown whereby the peg and location indicators on the top surface are removed and the top surface typically finished in a variety of designs to make a 'capping stone.' Such top surface can be tapered down to the sides from the longitudinal centre line as shown, or other practical and aesthetic finish applied, to enable water to run off and not accumulate.

In figure 8 an alternative configuration shows the underneath surface of a 'capping stone' featuring two sets of cut outs to allow versatility in construction when laying and assembling the top layers of interlocking blocks. Such versatility, for example, will allow a capping stone to be terraced in a staggered manner on either side.

In figure 9 a side perspective view of an alternative embodiment of interlocking block in the form of a 'capping stone' shows a top surface tapered down to the perimeter from the longitudinal centre line. In figure 10 in an alternative embodiment the underside perspective view of a half- block 'capping stone' is depicted, which is cut short lengthwise to be able to complete the end of typically a stretcher bond type build, whereby the ends of all such interlocking blocks line up vertically together. Channel 7 friction-fits stud or peg 5 featured in figure 1 in a 'floating' configuration along the length of the channel. In figure 11 two cut-outs are depicted. The extra cut-out, 8b enables stud or peg 5, featured in figure 1 to engage securely when a plurality of interlocking blocks are stacked, post manufacture, for packaging, carriage and transport purposes. In figure 12 a low angle perspective view shows stud or peg 5, typically but not exclusively, one third the depth of an interlocking block, sited such that another identical interlocking block can be laid over the top and another one underneath and so on, to complete the build of a retaining wall in a stretcher-bond style. Mortise-style protrusion 12 can be tapered as shown to facilitate easy engagement with tenon-style recess, or slot 11 in another interlocking block. Such mortise engagement facility may consist of a narrow protrusion or one which extends for part of, or the whole width of the interlocking block across the curvilinear face of the concave end; similarly with the tenon-style tapered recess 11 which may extend for part of, or the whole width of the interlocking block across the curvilinear face of the convex end.

Figure 13 shows a third angle projection of an alternative embodiment of the underneath face of an interlocking block. Modified slot 13 allows stud or peg 5 in another interlocking block to float dry in several positions bounded by the extremities of the curvilinear walls of the slot to suit the design of the retaining wall build. Engagement slots 1 facilitate carrying and transport to site. In another alternative embodiment chamfers 15 on all right angle connections facilitate easier fit for assembly of a plurality of blocks and for easier separation from a manufacturing mould in production. In figure 14 a top plan x-ray view features two layers of interlocking blocks depicting a curvilinear assembly. To effect such an overall contoured shape peg 5 interlocks within channel 7 and cut-out 8a of adjacent blocks above, in front and behind. Convex and concave ends, 2 and 3 respectively, nest into adjacent blocks to ensure there is no sideways deviation when connecting one block to another. The assembly of a plurality of interlocking blocks preferably begins at one end until a row is complete and then a second layer is started where the first started and so on until a desired retaining wall is completed.

In figure 15 three underneath views are depicted of an interlocking block which features a through channel 7 in all three and different positions of locating peg 5, shown as a black circle. The purposes of these different positions are so that in view A, a plurality of interlocking blocks can be vertically stacked for transport; in view B, a plurality of interlocking blocks can be vertically stacked in a straight-sided wall configuration; in view C, a plurality of interlocking blocks can be stacked in a staggered or terraced configuration where the embankment to be retained is sloping away from the vertical. In figures 16a and 16b two different views depict an alternative embodiment of an interlocking block laid on the side featuring four truncated comers which form ridges. Such an embodiment when nested into other identical blocks and laid end to end on the ground to form a straight assembly and interlocked with a plurality of blocks in all four directions creates block paving.

Figures 17a and 17b feature two different views of a three tiered example of a plurality of assembled interlocking blocks laid on their sides to form paving. Such an assembly requires only the perimeter of the paving to be secured by a suitable adhesive, concrete for example.

It will be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

The foregoing description details certain preferred embodiments of the present invention and describes the best mode contemplated. It will be appreciated, however, that changes may be made in the details of construction and the configuration of

components without departing from the spirit and scope of the disclosure. Therefore, the description provided herein is to be considered exemplary, rather than limiting, and the true scope of the invention is that defined by the following claims and the full range of equivalency to which each element thereof is entitled.

Claims

An interlocking block having a concave shape at one end and a convex shape at the other end, comprising an offset stud or peg on the upper surface which engages into a channel, or plurality of slots on the underneath surface of another identical interlocking block to form a stretcher bond style connection such that each block when laid against each other or placed on top of each other is locked in place to create any combination of vertical or terraced curvilinear or straight forms, which match the profile of an embankment or wall to be retained, or paving to be laid, when a plurality of interlocking blocks is assembled.

An interlocking block according to claim 1 , in which the concave end features a protruding mortice-style locating tongue and the convex end features a recessed, tenon-style groove, or slot.

An interlocking block according to claim 1 , in which positional location markers are sited around the perimeter of the convex end and the concave end respectively in such a manner that the aforesaid markers are visible on the top surface when a plurality of interlocking blocks are connected horizontally.

An interlocking block according to claim 1 , in which a circular location peg is offset in the top surface with a maximum height above the surface of less than the thickness of an interlocking block.

An interlocking block according to claim 1 in which the width of a channel running longitudinally underneath matches the diameter of the location peg in claim 4.

An interlocking block according to claim 5, in which the channel is not continuous.

An interlocking block according to claim 1 , in which a semi-circular shape is cut out from the channel in such a position that a location peg from another interlocking block when fitted into the semi-circular cut-out underneath can form a stretcher-bond type assembly format in side elevation and in end elevation a terraced assembly format in order to build up a plurality of connected blocks which forms a secure retaining wall.

An interlocking block according to claim 1 in which the four corners are truncated to facilitate in-line assembly, end to end.

An interlocking block according to claim 1 and claim 7 in which a plurality of assembled blocks are laid on their sides on the ground and connected to form paving; such interlocking blocks rendering random selection impossible.