Interlocking building block

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DESCRIPTION

Interlocking building block

BACKGROUND OF THE INVENTION

[0001] The present invention relates generally to a building block for building a self-supporting wall without mortar, the building block having an interlocking and flat surfaces extending outwardly from the interlocking, and having at least one core and further having a secondary core or end portion formed at each end of the building block to be seated over a socket of an adjacent lower building block.

[0002] Gimmick automobiles have rear slick tires mounted which are flat tires with little or no tread. The relatively large amount of surface area grips the road better for acceleration. The treads decrease the amount of grip and therefore decrease acceleration.

[0003] World War II jeeps had relatively thin tires. The thinner the tire, the more pressure per tire area on the part of the tire penetrating the mud or sand, and the better the traction.

[0004] The lessons of smoothness and pressure, well known in the automotive arts, have been overlooked by manufacturers of building blocks. A large number of building blocks have holes or slots to perform various functions. Also, a large number of building blocks have extensions or projections or protrusions to perform various functions. Often, if not most of the time, these building block recesses or extensions necessarily transfer the load bearing function to other parts of the building block. Such a transfer may place an undue amount of stress on these other parts of the building block or it may unbalance the block or a wall formed by such blocks.

[0005] Thanks to the lessons of smoothness and pressure, a self-supporting and mortarless wall can be constructed according to the present invention, with great stability with or without internal pipes.

[0006] US Patent 1, 657,861 describes a building wall comprising hollow building blocks, openings in the upper and lower walls of said building blocks, semi-circular cutout portions at the ends of said building blocks in combination with cylindrical collars gaps, said collars in openings in the wall of a row of blocks and in the opening formed by the joining of the semicircular cut-outs of the adjacent blocks at the superimposed level.

[0007] According to the present invention, there is a building block, comprising:

a) first and second load-bearing faces, wherein the first and second load-bearing faces are arranged opposite each other, wherein the first and second load-bearing faces are arranged generally parallel to each other, wherein the first and second load bearing faces are substantially spindles:

b) first and second ends, wherein the first and second ends are arranged opposite each other, wherein each of the first and second ends is transverse to each of the first and second load-bearing faces;

c) first and second sides, where the first and second sides are arranged opposite each other, where the first and second sides are arranged generally parallel to each other, where each of the first and second sides is transverse to each of the first and second load bearing faces and at each of the first and second ends;

d) a first inner core formed in the building block and extending to and between the load bearing faces, wherein the first inner core is spaced from each of the first and second ends, and wherein the first core interior is separated from each of the first and second sides;

e) a core end portion formed at each first and second end, the core end portion extending to and between the load bearing faces;

the building block further comprising:

f) an interlock projecting from one of the load-bearing faces and forming at least a part of a periphery of the first inner core, where the interlock and core end portion are configured such that an interlock of one element can confront a surface that forms a core end portion of another confronted building block and where the core end portion is not vertically aligned with an interlock overhang in the same building block,

g) so that, by staggering building blocks to each other in first and second levels, an interlock of a building block in the first level can be received in a core end portion of a building block in the second level;

characterized in that the size of the interlock is large enough so that the interlock is excluded from being received in the first inner core.

Summary of the invention

[0008] A feature of the present invention is the provision in a building block that has at least one core and a pair of secondary or end core parts that form secondary cores with adjacent building blocks, of an interlock protruding from a load bearing face of the building block and forms at least a portion of the periphery of the core for reception in a secondary core portion of an adjacent building block positioned at an adjacent level.

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[0009] Another feature of the present invention is the provision of a building block having at least one core and a pair of a pair of secondary or end core parts that form secondary cores with adjacent building blocks, of an interlock protruding from a load bearing face of the building block and forms at least a portion of the periphery of the core for reception in a secondary core portion of an adjacent building block positioned at an adjacent level, and of the interlock being arched and continuous and running along a perimeter of the nucleus.

Another feature of the present invention is the provision of a building block having at least one core and a pair of secondary or end core parts that form secondary cores with adjacent building blocks, of an interlock protruding from a load bearing face of the building block and forming at least a portion of the periphery of the core for reception in a secondary core portion of an adjacent building block positioned at an adjoining level, first and second load bearing faces of the building block being substantially flat regardless of interlocking, and the first and second load bearing faces being parallel.

Another feature of the present invention is the provision in a building block that has at least one core and a pair of secondary or end core parts that form secondary cores with adjacent building blocks, of an interlock protruding from a load bearing face of the building block and forms at least a portion of the periphery of the core for reception in a secondary core portion of an adjacent building block positioned at an adjacent level, and of the buckling having a dividing wedge such that separate interlocking first and second segments are formed.

Another feature of the present invention is the provision in a building block that has at least one core and a pair of secondary or end core parts that form secondary cores with adjacent building blocks, of an interlock projecting from a load bearing face of the building block and forming at least a portion of the periphery of the core for reception in a secondary core portion of an adjacent building block positioned at an adjacent level, and of two opposite sides of the building block that are textured so that the two opposite sides are aesthetic. [0013] Another feature of the present invention is the provision in a building block that has a set of three cores and a pair of secondary or end core parts that form secondary cores with adjacent building blocks, of interlocks projecting from a load bearing face of the building block and forming at least a part of the periphery of two respective cores for reception in respective secondary core parts of adjacent building blocks positioned at an adjacent level

[0014] Another feature of the present invention is the provision in a building block that has a set of three cores and a pair of secondary or end core parts that form secondary cores with adjacent building blocks, of interlocks protruding from a load bearing face of the building block and form at least a part of the periphery of two respective cores for reception in respective secondary core parts of adjacent building blocks positioned at an adjacent level, and of a wedge divider forming a portion of a core to provide an aid for dividing the block in the field.

[0015] Another feature of the present invention is the provision in a building block that has a set of three cores and a pair of secondary or end core parts that form secondary cores with adjacent building blocks, of interlocks projecting from a load bearing face of the building block and forming at least a part of the periphery of some two respective cores for reception in respective secondary core parts of adjacent building blocks positioned at an adjacent level, and a dividing wedge that cuts through an interlock to provide an aid in dividing the block in the field.

[0016] Another feature of the present invention is the provision in a building block that has a set of three cores and a pair of secondary or end core parts that form secondary cores with adjacent building blocks, of interlocks protruding from a load-bearing face of the building block and forming at least a part of the periphery of the two respective cores for receiving in respective secondary core parts of adjacent building blocks positioned at an adjacent level, and of the two cores being of different size, one small enough to exclude the seat from an interlocking of a potentially adjacent building block, and one large enough to accommodate an interlocking of an adjoining building block.

[0017] Another feature of the present invention is the provision in a building block having a set of two cores and a secondary or end portion of the core at one end of the building block, of the two cores being of different size, one small enough to exclude the seat from a potentially adjacent building block interlocking, and large enough to accommodate an adjoining building block interlocking.

[0018] An advantage of the present invention is stability. The building blocks present can form a self-supporting, mortar-free, highly stable wall without pipes. One feature that contributes to this advantage is interlocking. Another feature that contributes to this advantage is the flatness d of the upper and lower load bearing faces which causes the load to be transmitted evenly over a maximum amount of surface area.

[0019] Another advantage of the present invention is that pipe can be incorporated into the self-supporting wall without mortar. When such a wall is built, the cores are naturally aligned to allow the placement of pipes in it.

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[0020] Another advantage of the present invention is that the current blocks can settle in some cores and not in others. That natural selection and exclusion ensure a self-aligning and error-free wall.

[0021] Another advantage is that the building block can be used as a base for a single wall. For example, the interlock and its coupling to the corresponding secondary or core end portion are structured to allow building blocks of one configuration to form either a straight wall or a curved wall. Also, the ends of the building block are oblique so that a set of basic building blocks having a shape can form a straight wall or a curved or wavy wall. Additionally, the interlock and its secondary mating core portion can be rotationally adjusted and still fit, such as when the owner saws or spreads the end of the building block to make their own unique angle or bend. Furthermore, the secondary core portion is formed relatively deep in the building block such that a recess still remains in the building block for interlocking when a homeowner cuts such an end of the building block.

[0022] Another advantage is that a self-supporting wall constructed from a set of the present building blocks is secure with or without glue, is secure with or without posts, is secure while being built, is secure after completion, and is safe for a large number of years. For example, the present building block has inner cores and secondary (or end) core portions so that it is hollow and relatively lightweight and easy to handle for the do-it-yourself homeowner. In addition, the interlocks minimize the movement of newly placed building blocks both to minimize the fall of walls under construction. Additionally, some anchors have spacer wedges that allow field modification. Also, posts can be inserted through any of the cores or do not need to be inserted at all.

[0023] Another advantage is the ability to build with high structural stability when building serpentine or curved walls.

[0024] Another advantage is the ability to build with high structural stability when building zigzag walls.

[0025] Another advantage is the ability to achieve rigidity with or without pipes. When used, a lower part of the pipe is buried in the ground and an upper part of the pipe faces internal cores, specifically the interlocking cores.

Another advantage is that the self-supporting wall can be easily removed by a later owner. The self-supporting wall constructed by a set of the present building blocks does not require rebar, posts, glue, or relatively deep holes dug into the ground. Furthermore, the present building block is relatively hollow to minimize the mass that must be removed by a homeowner with different tastes.

Another advantage is that the present building block is relatively cheap to manufacture.

[0028] Still other features and advantages of the present invention will become apparent to those skilled in the art after a review of the specification and accompanying drawings.

IN THE DRAWINGS

[0029]

Figure 1 is a perspective view of the angle block of the present invention having a continuous interlock.

Figure 2A is a top view of the angle block of Figure 1.

Figure 2B is a side view of the angle block of Figure 2A.

Figure 3A is a top view of the angle block of the present invention having a dividing wedge in the interlock.

Figure 3B is a side view of the angle block of Figure 3A

Figure 4 is a top view of the mold arrangement for the angle blocks of Figures 2A and 3A. Figure 5A is a top view of the tensioner block of the present invention with a pair of continuous interlocks.

Figure 5B is a side view of the tensioner block of Figure 5A.

Figure 6A is a top view of the tensioner block of the present invention having a dividing wedge in the central core.

Figure 6B is a side view of the tensioner block of Figure 6A.

Figure 7A is a top view of the tensioner block of the present invention having a dividing wedge in one of the interlocks.

Figure 7B is a side view of the tensioner block of Figure 7A.

Figure 8 is a top view of a mold design for the tensioner blocks of Figures 5A, 6A and 7A.

Figure 9A is a top view of a corner block.

Figure 9B is a side view of the corner block of Figure 9A.

Figure 10 is a top view of a mold design for the corner block of Figure 9A.

Figure 11A is a top view of a lid block.

Figure 11B is a side view of the cap block of Figure 11A.

Figure 12 is a top view of a mold design for the lid block of Figure 11 A.

Figure 13A is a top view of a post cap block.

Figure 13B is an end view of the post cap block of Figure 13A.

Figure 13C is a side view of the post cap block of Figure 13A.

Figure 14 is a top view of the mold arrangement for the post cap block of Figure 13A. Figure 15A is a top view of a straight wall portion using the angle block of Figure 2A.

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Figure 15B is a top view of a straight wall portion using the tensioning block of Figure 5A. Figure 16A is a top view of a curved wall portion using the angle block of Figure 2A. Figure 16B is a top view of a curved wall portion using the angle block of Figure 2A, a portion of the angle block of Figure 3A, the tensioning block of Figure 5A, and the corner block of Figure 9A.

Figure 17A shows a part of a corner of a wall formed by corner blocks of Figures 9A and 9B.

Figure 17B shows a masonry post formed by corner blocks of Figures 9A and 9B. Figure 18A shows a portion of the wall using tubing for wall roll resistance.

Figure 18B shows how a wall can be given an arbitrary appearance using blocks of the present invention.

Figure 19A is a top view of a portion of a serpentine wall that has a relatively large amount of stability.

Figure 19B is a top view of a portion of another type of serpentine or zig-zag wall that has a large amount of stability.

DESCRIPTION OF THE PREFERRED EMBODIMENT

According to a preferred embodiment of the present invention, a set of building blocks for one or more parts of a self-supporting wall without mortar having two opposite textured sides, includes an angle block 10 shown in Figures 1, 2A and 2B, an angle block 12 having a dividing wedge and shown in Figures 3A and 3B, a tensioning block or double unit block 14 shown in Figures 5A and 5B, a tensioner block or double unit block 16 having a dividing wedge in the central core and is shown in Figures 6A and 6B and a tensioning block or double unit block 18 having a dividing wedge in the interlock and shown in the Figures 7A and 7B. Furthermore, the figures show a corner block 20 shown in Figures 9A and 9B, a cap block 22 shown in Figures 11A and 11B, and a post cap block 24 shown in Figures 13A and 13B that are not preferred embodiments of the invention.

[0031] Angle block 10

As shown in Figures 1, 2A and 2B, angle block 10 generally includes a first load bearing face 30, a second load bearing face 32, a first end 34, a second end 36, a first side 38, and a second side 40. Angle block 10 further includes a first or central or inner or main core 42 defined by a cylindrical or core wall 44, a secondary or final core or arcuate end recess or seat 46 defined by a cylindrical or core wall 48, a secondary or end portion of the core or arcuate end recess or seat 50 defined by a cylindrical or core wall 52, and a continuous interlock 54 around a perimeter of the main core 42. Angle block 10 further includes four corner faces or chamfers 56, 58, 60, and 62.

As shown in Figures 2A and 2B, the first load bearing face 30 is arranged opposite the second load bearing face 32. Each of the load bearing faces 30, 32 is arranged in a plane that is parallel to the plane of the other load-bearing face. Each of the load bearing faces 30, 32 is transverse to or in a transverse direction relative to the ends 34, 36 and the sides 38, 40. Generally, each load bearing face 30, 32 is trapezoidal. Specifically, each of the load bearing faces 30, 32 is delimited by a set of 12 edges formed by the corner faces or chamfers 56, 58, 60 and 62, the ends 34, 36 having the secondary walls 48, 52, and sides 38, 40.

The main core 42 is formed centrally at angle block 10 and extends to and between each of the load bearing faces 30, 32. A central axis formed through main core 42 is equidistant from side 38 and the side 40 and is further equidistant from a midpoint at end 34 and a midpoint at end 36.

The main core 42 is an inner core. That is, the main core 42 is spaced from each of the first and second sides 38, 40 and from each of the first and second ends 34, 36.

The diameter or size of the main core 42 in combination with the size of the secondary core portions 46, 50 is large enough to minimize the weight or mass of the angle block 10 and small enough to provide sufficient mass and strength. to the angle block 10 so that a set of angle blocks 10, alone or in combination with other building blocks, can constitute a self-supporting wall.

[0037] A continuous interlock 54 runs a perimeter of the main core 42 on the main load bearing face 30 so that it is curved or arched to cooperate with one of a secondary core wall of an adjacent building block, such as walls of secondary cores 48, 52 of an adjacent angle block 10, which is placed on an immediately contiguous level. Such a curved or arcuate shape, or more preferably a circular shape, and most preferably a continuous circular shape, allows rotational adjustment of the angle block 10 relative to another building block while maintaining an interlock between the blocks. Building blocks interlock when two adjacent blocks are placed on the same end-to-end level, preferably without glue, so that confronting secondary core parts form a secondary core and therefore a receptor for continuous interlocking 54 of a building block, such as angle block 10, on an immediately adjoining level.

[0038] It can be seen from a sectional view that the continuous interlock 54 includes a cylindrical wall surface portion 70, which runs parallel and in line with the cylindrical wall 44, an upper portion of the continuous surface 72 running outward from the cylindrical portion of the wall surface 70 and extending generally parallel to the load bearing face 30, and a continuous tapering or beveled surface 74 tapering from the continuous surface top 72 to the supporting face of

ES 2 415 768 T3 load 30. Once again, the seat for continuous interlock 54 is a secondary core made up of two secondary core parts. Said secondary core or seat includes walls of secondary core portions, such as walls 48, 52, that run normal to a second load bearing face, such as face 32. The continuous beveled or tapered surface 74 aids in interlock alignment continuous 54 with the walls of the secondary core parts. The radius of the continuous interlock 54, measured at the intersection between the tapering or continuous chamfered surface 74 and the load bearing face 30, is substantially equal to, and preferably slightly less than, the radius of the secondary core walls, such as as secondary walls of cores 48 and 52. Continuous interlock 54 is molded or formed at the same time as angle block 10 so that continuous interlock 54 is one piece with and integral with angle block 10.

[0039] End 34 is disposed opposite end 36. End 34 includes a first generally flat surface or face 80 and a second generally flat surface or face 82, with each of the pin surfaces 80, 82 running normal to the load bearing faces 30, 32. The secondary core portion 46 is formed intermediate the flat surfaces 80, 82. The flat surfaces 80, 82 lie in a plane that is oblique to each of the sides 38, 40. End 36 includes a first, generally flat surface 84 and a second, generally flat surface 86, with each of the flat surfaces 84, 86 going perpendicular to the load bearing faces 30, 32. The secondary core portion 50 is formed between flat surfaces 84 and 86. Flat surfaces 84, 86 lie in a plane that is oblique to each of sides 38, 40. The plane in which the flat surfaces 80, 82 are arranged is relatively oblique to the plane in which the flat surfaces 84, 86 are arranged. Each of the flat surfaces 80, 82, 84, 86 is transverse to or lies in a transverse direction with respect to faces 30, 32 and sides 38, 40. By virtue of the mutually inclined ends 36, 38, a set of angular blocks 10, alone or in combination with other blocks, can form either a curved row of blocks or a straight row of blocks or a combination of both to form, for example , an undulating or serpentine row of blocks. As shown in Figure 16A, a continuous curved row of blocks is formed when each of the sides 38 confronts or aligns with each of the other sides 38. As shown in Figure 15A, a straight row of blocks is formed when the blocks are laid front to back in such a way that the side 38 of one block meets the side 40 of the immediately adjacent block which in turn meets with the next block side 38 immediately adjacent, continuing such a continuous pattern at a desired length. An undulating row of blocks can be formed by a combination of straight and curved row portions.

The sides 38, 40 of the angle block 10 are arranged opposite each other. Each of the sides 38, 40 is generally arranged in a plane that is generally parallel to the plane of the other side. Each of the sides 38, 40 is transverse to or in a direction transverse to the load bearing faces 30, 32 and to the ends 34, 36. The sides 38, 40 form the vertical outer faces of the self-supporting wall. The sides 38, 40 are preferably textured to form a textured double-sided wall.

12 angle block with a dividing wedge

[0041] As shown in Figures 3A and 3B, angle block 12 is identical to angle block 10 with the exception of a dividing space or slot or recess 90 that cuts the interlock to form a discontinuous interlock 92 with interlocking segments 94. Each of the interlocking segment 94 has a pair of ends or end faces 96 that are spaced from the ends or end faces 96 of the other interlocking segment 94 to form the dividing space 90 between them. The space 90 runs to and between each one of the load bearing faces 30, 32. The space 90 opens to and communicates with the inner core 42.

[0042] Space 90 is a marker or an aid for dividing angle block 12, such as in the field, into at least two portions along a plane 98 running substantially normal to faces 30, 32. Once divided, such as with a chisel or other wedge tool or saw, the right-hand and left-hand straight blocks are formed. One part or block 100 forms a left straight building block and one part or block 102 forms a right straight building block such that each of the portions 100, 102 has a face formed by plane 98 which is normal. to their respective sides 38 and 40 and oblique to their respective surfaces 80, 82 and 84, 86.

The angle block 12 does not require modification in the field. If possible, angle block 10 with continuous interlock 54 is preferred. However, when angle block 10 is not available, angle block 12 can substitute for angle building block 10.

Mold design for 10 and 12 angle blocks

[0044] As shown in Figure 4, a preferred way to form a rough masonry face or texture on the sides 38, 40 is by splitting molded blocks back to back, as in a partitioning machine. For example, a mold box 103 can be set up so that the sides 38 of two different blocks 10 are back to back and that the faces 40 of two different blocks 10 are back to back. Therefore, the blocks 10 are split along the sides 38 and the sides 40 to create the texture.

[0045] In Figure 4, the portions of the mold are indicated by the redeferential number 04 and confront, for example, at least the load bearing surfaces 30, 32, the first end 34 including the wall 48 and the surfaces 80, 82, a second end 36 including wall 52 and surfaces 84 and 86, cylindrical wall 44, cylindrical wall portions 70 of latch 54, upper surface 72 of latch 54, tapered or beveled surface 74, chamfers 56 , 58, 60, and 62, and, where interlocking segments 94 are formed, the ends or end faces 96 and load bearing surface portions 30 that run to and between the interlocking segments 94.

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[0046] In Figure 4, spare parts of masonry are indicated by reference numerals 106 and separated from their respective faces 38 or 40.

Tensioner block or double unit blocks 14

[0047] Tensioner or double unit block 14 is shown in Figures 5A and 5B. Dual unit block 14 includes a first load bearing face 110, a second load bearing face 112, a first end 114, a second end 116, a first side 118, and a second side 120.

Tensioner block 14 further includes a relatively large or central second inner core 122 defined by a core or cylindrical wall 124 and, on each side of the relatively large second inner core 122, a pair of relatively small first inner cores 126, 128 defined by respective cylindrical or core walls 130, 132.

[0049] Tensioner block 14 further includes a secondary or core end portion or arcuate end recess or seat 134 defined by a cylindrical or core wall 136 and a secondary or core end portion or arcuate end recess or seat 138 defined by a cylindrical or core wall 140.

The tensioner block 14 further includes a continuous interlock 142 around a relatively small inner core perimeter 126 and a continuous interlock 144 around a relatively small inner core perimeter 128.

The tensioner block 14 further includes four corner faces or chamfers 146, 148, 150 and 152.

The first load bearing face 110 is arranged opposite the second load bearing face 112. Each of the load bearing faces 110, 112 is arranged in a plane that is parallel to the plane of the other. load bearing face. Each of the load bearing faces 110, 112 is transverse to or in a transverse direction relative to the ends 114, 116. Generally, each of the load bearing faces 110, 112 is a parallelogram. Specifically, each of the load bearing faces 110, 112 is delimited by a set of 12 edges formed by the corner faces or chamfers 146, 148, 150, and 152, the ends 114, 116 having the secondary walls or recesses 136, 138, and sides 118, 120.

The central core 122 is centrally formed in the tensioning block 14 and extends to and between each of the load bearing faces 110, 112. An axis running centrally through the central core 122 is equidistant from the sides 118 and 120 and is further equidistant from a midpoint at end 114 and a midpoint at end 116.

The diameter or size of the central core 122, in combination with the diameter or size of the relatively small inner cores 126, 128, and further in combination with the diameter or size of secondary core parts 134, 138, is sufficiently large to minimize the weight or mass of the tensioner block 14 and small enough to provide sufficient mass and strength to the tensioner block 14 so that a set of tensioner blocks 14, alone or in combination with other building blocks, it can form a self-supporting wall.

[0055] Each of the cores 122, 126 and 128 is an inner core. That is, each of the cores 122, 126, 128 is spaced from each of the first and second sides 118, 120 and each of the cores 122, 126, and 128 is spaced from each of the ends 114, 116. Each of the cores 122, 126 and 128 is separate from the others.

[0056] Each of the continuous enervations 142, 144 runs around the perimeter of their respective inner core 126 and 128 on the first load bearing face 110 so that it curves or arches to cooperate with one of a secondary wall of core of an adjacent building block and placed on an immediately adjacent level. Such a curved or arcuate shape, or more preferably a circular shape, and most preferably a continuous circular shape, allows rotational fit between confronting building blocks while maintaining an interlocking between the blocks. The tensioning block 14 interlocks with other building blocks when two adjacent blocks are placed abutting, preferably without glue, so that when facing secondary core parts they form a secondary core and therefore a receptor for one of the continuous enervations 142,144 in an immediately adjacent level.

The continuous enervations 142,144 are identical in shape to the continuous interlock 54 and are composed of a cylindrical wall surface portion 154 that runs parallel and in line with its respective cylindrical wall 130, 132, a continuous annular surface top portion 156 running outward from the cylindrical wall surface portion 154 and extending parallel to the load bearing face 110, and a continuously tapered or beveled surface tapering from the continuous surface top 156 to the first load bearing face 110.

[0058] A seat for continuous enervations 142, 144 is a secondary core formed by two confronting secondary core portions. Said secondary core or seat includes secondary core portion walls, such as walls 48 and 52 of angle block 10 or angle block 12 or walls 136 and 140 of tensioner block 14, tensioner block 16, and tensioner block 18 , or secondary core portion walls of corner block 20. These secondary core portion walls run normal to a second load bearing face, such as face 112.

[0059] Another seat for the continuous ribs 142, 144 is the cylindrical wall 124 of the main core 122. The cylindrical wall 124 of the main core 122 is also a seat for the continuous interlock 54 or the discontinuous interlock 92 or any of the segments of interlock 94.

Like the continuous interlock 54, the continuous ribs 142 and 144 include the continuous tapered or chamfered surface that helps align the ribs 142 and 144 with the walls of the secondary core portions. Like interlock 54, each of the enervations 142 and 144 has a radius, measured at the intersection between the tapering surface and the first load-bearing face 110, which is

ES 2 415 768 T3 substantially equal to, and preferably slightly less than, the radius of the secondary core walls, such as the secondary core walls 48, 52, 136, and 140. Continuous interlocks 142 and 144 are molded or formed therewith. time than tensioner block 14 such that continuous interlocks 142 and 144 are one-piece and integral with tensioner block 14.

[0061] End 114 is disposed opposite end 116. End 114 includes a generally planar first face or surface 160 and a generally planar second face or surface 162, with each of the planar surfaces 160, 162 going perpendicular to each other. Load bearing faces 110, 112. Secondary core portion 134 is formed intermediate between flat surfaces 160, 162. The flat surfaces 160, 162 lie in a plane that is oblique to each of the sides 118 and 120.

[0062] End 116 includes a generally planar first face or surface 164 and a generally planar second face or surface 166, with each of planar surfaces 164,166 perpendicular to load bearing faces 110, 112. The secondary core portion 138 is formed intermediate the flat surfaces 164, 166. The flat surfaces 164, 166 lie in a plane that is oblique to each of the sides 118 and 120. The plane in which the plane surfaces 160, 162 lie is parallel to the plane in which the pair of plane surfaces 164,166 lie.

Each of the flat portions 160, 162, 164 and 166 is transverse to or is in a transverse direction with respect to the faces 110, 112 and the sides 116, 118.

[0065] Because the ends 114, 116 have parallel flat surfaces, the butt-set tensioning blocks 14 form a straight line or wall portion. In such a straight wall portion, since the ends 114, 116 have parallel flat surfaces, the sides 118 may be aligned with each other or the side 118 may be aligned with the side 120.

In the upper part of said straight wall portion, other tensioning blocks 14 can be placed in a staggered relationship such that one of the continuous interlocks 142, 144 of a lower block 14 is seated in a secondary core formed by two facing parts of secondary core 134 and 138 of the upper straight wall part and such that the other interlocks 142, 144 of upper block 14 are seated in a central core 122 of upper block 14. Such a staggered relationship forms a building block interlocking wall.

The tensioner block 14 can be used in combination with angle blocks 10, 12 to provide curves in walls or wavy or serpentine patterns in the walls formed by blocks 10, 12, 14, 16, 18, and 20.

The sides 118, 120 of the tensioning block 14 are arranged opposite each other. Each of the sides 118, 120 is generally arranged in a plane that is generally parallel to the plane of the other side. Each of the sides 118, 120 is transverse to or is in a transverse direction with respect to the load bearing faces 110,112 and the ends 114,116. Sides 118, 120 form the vertical outer faces of the self-supporting wall. Sides 118, 120 are preferably textured to form a double-sided textured wall.

[0069] Tensioner block or double unit block 16 with a spacer wedge in the main core

[0070] As shown in Figures 6A and 6B, the tensioner block 16 is identical to the tensioner block 14 with the exception of a pair of dividing wedges or recesses 170 in the central core 122. The separating wedges 170 are aligned with each other and they are arranged in a plane running normal to the load bearing faces 110, 112 and to the sides 118, 120. Each of the recesses 170 runs through and between the first and second load bearing faces 110, 112. Each of the recesses 170 communicates with or opens to the central core 122.

[0071] The spacer wedges 170 serve as an aid for field modification of the tensioner block 16. That is, by dividing the block 16 along the plane defined by the pair of dividing wedges 170, a block or portion of left straight block 172 and a left straight block or block portion 174, with each of the newly formed blocks 172, 174 having secondary wall portions or seats for interlocks.

[0072] It should be noted that the tensioning block 16 does not require modification in the field and can, if desired, be used in the same way as the tensioning block 14.

Tensor Block or Double Unit Block 18 with a Distractor Wedge in an Interlock

[0073] As shown in Figures 7A and 7B, tensioner block 18 is identical to tensioner block 14 with the exception of a dividing wedge 180 (or recesses 180) in order to form a discontinuous interlock 182 having a pair of segments. interlocking 184, 186.

[0074] Discontinuous interlock 182 is the same as discontinuous interlock 92 such that one interlock segment 184 has a pair of ends or end faces 188 that are spaced from the ends or end faces 188 of another interlock segment 186 in order to form the dividing wedge or space or recess 180 between them. The space 180 runs to and between each of the load bearing faces 110, 112. Space 180 opens to and communicates with inner core 128.

[0075] The spacer wedge 180 is a marker or an aid for dividing the tensioning block 18 into a one-quarter portion or left straight block 190 and a three-quarter portion or left straight block 192. The spaces 180 are aligned with each other in a plane that goes normal to ends 110, 112 and sides 118 and 120. Once divided, blocks 190 and 192 have end faces that go normal to ends 110, 112 and sides 118 and 120.

It should be noted that tensioner block 18 does not require field modification and can, if desired, be used in the same way as tensioner block 18.

Mold Design for tension blocks 14. 16, and 18

ES 2 415 768 T3

[0077] As shown in Figure 8, a preferred way to form a rough masonry face or texture on sides 116, 118 is by dividing one or more tensioner blocks 14, 16, and 18 molded back to back, such as on a cutting machine. For example, the mold box 194 includes an arrangement having a tensioning block 14, a tensioning block 16, and a tensioning block 18, where the sides of blocks 14 and 16 are formed by a partition and where blocks 14 and 18 meet. formed by division. One side of block 16 is formed by partition with excess masonry portion 196. One side of block 18 is formed by partition with excess masonry portion 198. Other block portions 14, 16 and 18 face portions of mold 200 and these other portions of blocks 14, 16 and 18 include at least faces 110, 112, ends 114, 116, cylindrical wall 124 of central core 122 , cylindrical walls 130, 132 of relatively small inner cores 126 and 128, interlocks 142 and 144, chamfers 146, 148, 150, and 152 and, in block 16, recesses 170 and furthermore in block 18, the recesses 180.

Corner block 20

[0078] As shown in Figures 9A and 9B, corner block 20 generally includes a first load bearing face 202, a second load bearing face 204, a first end 206, a second end 208, a first side 210 and a second side 212. Corner block 20 further includes a central or main or inner core 214 defined by a cylindrical wall 216 and an inner core 218 defined by a cylindrical wall 220. Corner block 20 further includes four corner faces or chamfers 222, 224, 226, and 228 that are arranged in planes normal to load bearing faces 202, 204.

The first load bearing face 202 is arranged opposite the second load bearing face 204. Each of the load bearing faces 202, 204 is arranged in a plane parallel to the plane of the other load bearing face. load. Each of the load bearing faces 202, 204 is transverse or is in a cross direction relative to the ends 206, 208.

Generally, each of the load bearing faces 202, 204 is trapezoidal. Specifically, each of the load bearing faces 202, 204 is bounded by a set of ten edges formed by chamfers 222, 224, 226, 228, flat end 206, end 208 having a secondary core portion, and the sides 210, 212.

Central core 214 is formed generally centrally in corner block 20 and extends to and between each of the load bearing faces 202 and 204. An axis running centrally through central core 214 is equidistant from sides 210 and 212 and is also generally equidistant from ends 206 and 208.

More particularly, an axis 229 running centrally through central core 214 and an axis 231 running centrally through inner core 218 are spaced from each other by a distance equal to the distance between axis 231 and axis 233, which runs centrally through a portion of secondary core 230 from end 208, where secondary core portion 230 is defined by cylindrical wall 232.

Such distance established between axes 229 and 231 and between axes 231 and 233 is also the distance established between 1) the core axis 42 and the axis of each of the secondary core portions 46, 50 of the angle blocks 10 and 12; 2) the axis of the central core 122 and the axis of each of the inner cores 126 and 128 of the tensioning blocks 14, 16 and 18, 3) the axis of the inner core 126 and the axis of the secondary core portion 138 of the tensioning blocks 14,16 and 18, 4) the inner core axis 128 and the secondary core portion axis 134 of the tensioning blocks 14, 16

[0084] The diameter or size of the central core 214 in combination with the inner core 218 is large enough to minimize the weight or mass of the corner block 20 and small enough to provide sufficient mass and strength to the corner block 20 so that A set of corner blocks, alone or in combination with other building blocks, can make a self-supporting wall.

The corner blocks 20 do not include an interlocking device such as interlock 54. However, the cylindrical wall 220 of the inner core 218 has the same diameter as the cylindrical walls of 1) 44 and 70 of the angle blocks 10 and 12, and 2) cylindrical walls 130 and 132 of tensioning blocks 14, 16, and 18 so that pipe can be introduced through inner core 218 and the cores of other blocks 10, 12, 14, 16,18 and twenty.

Furthermore, it should be noted that the cylindrical wall 216 of the central core 214 has the same radius as the secondary core part 230, the radius of which is the same as 1) the secondary core parts 46, 50 of the blocks of angle 10 and 12; and 2) the central core 122 and the secondary core portions 134 and 138 of the tensioner blocks 14, 16 and 18.

Furthermore, it should be noted that the central core 214, like other central or main cores, is a seat for a continuous interlocking or one or more interlocking segments.

Furthermore, it should be noted that the secondary core part 230, like other secondary core parts, is a seat for a continuous interlock or an interlock segment.

[0089] End 206 is disposed opposite end 208. End 206 is flat and runs in a plane normal to load bearing faces 202, 204 and sides 210, 212. End 208 includes a first flat surface 234 and a second planar surface 236, with each of the planar surfaces 234, 236 running normal to the load bearing faces 202, 204. The secondary core portion 230 is formed intermediate the planar surfaces 234, 236. The flat surfaces 234, 236 lie in a plane that is oblique to each of the sides 210, 212 and which is further oblique to the plane in which the end 206 rests. Each of the flat surfaces 234, 236 is transverse to or meets in a direction transverse to faces 202, 204 and sides 210, 212.

[0090] Because flat end 206 and oblique end 208 have an interlocking seat or secondary core portion 230, corner block 20 may form a portion of a corner or end of a

ES 2 415 768 T3 self-supporting wall, with the flat end 206 possibly being a terminal portion of the corner or end of the self-supporting wall. Such a self-supporting wall or row of building blocks could then run from oblique end 208.

[0091] Sides 210, 212 of corner block 20 are arranged opposite each other. Each of the sides 210, 212 is generally arranged in a plane that is generally parallel to the plane of the other side. Each of the sides 210, 212 is transverse to or in a cross direction with respect to the load bearing faces 202, 204 and ends 206, 208. Sides 210, 212, and flat end 206 for vertical outer faces of a self-supporting wall are preferably textured to form a double-sided textured wall with corners or ends that are also textured.

The corner block 20 can be used right side up '' or the other way around. In other words, either of the load bearing faces can be on top of the other. Similarly, blocks 10, 12, 14, 16, and 18 can be used with any of the load bearing faces at a higher level.

Mold Design for Corner Block

As shown in Figure 10, a mold design 240 for corner block 20 includes three corner blocks 20 with dividing lines or planes 242 to form one or more of the textured sides 210, 212. Two of the Dividing planes 242 divide a corner block 20 from a portion of excess masonry 244.

The mold design 240 further includes dividing lines or planes 246 to form the flat end 206 and dividing the flat end 206 from an excess masonry portion.

The remaining parts of the corner block 20 face mold portions 250 and these other parts include at least the load bearing faces 202, 204, the end 208 with the secondary core part 230, the cylindrical core wall 216 relatively large center 214, the cylindrical wall 220 of the relatively small inner core 218, and bezels 222, 224, 226 and 228.

Cap block 22

[0096] As shown in Figures 11A and 11B, a cap or cap block 22 may be placed on an uppermost building block or row of uppermost building blocks 10, 12, 14, 16, 18 and / or twenty. Cap 22 includes two ends 260 and 262 that are mutually inclined to each other and are coplanar with, or preferably extend slightly beyond, ends 34 and 36 of angle blocks 10, 12 when cap 22 is placed on top. of angle block 10 or 12. Cap 22 further includes a flat top face 264 that faces a bottom face 266 that includes two flats 268, 270 with a track 272 intermediate the flat portions 268, 270. The flat portions 268, 270 and are arranged in a plane that is generally parallel to a plane in which the flat top face 264 rests. The lid 22 further includes sides 274, 276 that are opposite each other and that are arranged in planes that run parallel to each other and normal to the flat portions 268, 270. Track 272 is a receiver for an interlock, such as continuous interlock 54, discontinuous interlock 92, continuous interlocks 142, 144, and discontinuous interlock 182. When cover 22 is fitted onto one of the building blocks, the parts Slopes of track 278 confront sloped portions of such interlocks or interlocking segments.

It should be noted that the width of the cover 22 (distance between the sides 274 and 276) is greater than the width of any of the building blocks 10, 12, 14, 16, 18 and 20 (distance between the sides of such blocks) such that the lid 22 protrudes from said building blocks.

[0098] It should be noted that the cap 22 may or may not be placed directly on respective building blocks, but that the caps 22 may be staggered relative to the immediately lower building blocks. In other words, in a row of building blocks, a line is formed where two ends of the adjacent building blocks meet. A cap 22 can be placed directly on that line to hide where adjacent building blocks face each other.

[0099] Figure 18A shows cap blocks 22 positioned to form a cap of a straight wall portion such that side 260 of one cap block 22 faces side 262 of the other cap block 22. Mold Design for cap block.

[0100] As shown in Figure 12, the lid or lid block 22 preferably does not include any texture. Accordingly, in a mold design 280, where four caps or cap blocks 22 are formed, the cap blocks 22 are spaced apart and no partitions are formed anywhere. The mold portions 282 face each surface of the lid or lid block 22

Post Cap Block 24

[0101] Post cap block 24 is shown in Figures 13A, 13B and 13C. Post cap block 24 includes a top rectangular flat surface 284 and a set of three inclined surfaces 286, 288, and 290 that go down and out from the rectangular flat top surface 284. Surface 286 goes inward from one side full-length 292 and each surface 288 and 290 is directed to respective half-length sides 294 and 296. Surfaces 288 and 290 further go to a rear 298. Post cap block 24 further includes a flat bottom surface 300.

[0102] When two post cap blocks 24 are placed back to back so that the rear sides 298 face each other, a post cap is formed to be placed on top of a post, such as post 312 (shown in Figure 17B in the construction process). Said post cap includes a square flat top surface formed by two inclined surfaces 284 and four surfaces extending downward and outward from the flat top square surface, where two of the four inclined surfaces are two surfaces 286 and where the other two of the four inclined surfaces are formed by a

The post cap then has the appearance of a crown. The surface of such a crown is defined by said four inclined or trapezoidal areas that converge upwards towards the square planar surface that can be used to mount a light fixture. The post cap block 24 is preferably glued or otherwise attached to the flat surfaces of the tops of a post, where such post is more preferably formed by corner blocks 20 or by a combination of building blocks 10, 12 , 14, 16, 18, and 20. Post cap block 24 preferably has a length and width sufficient to extend beyond one, two, three, or four sides of a post.

Mold Design for Post Cap Block

[0103] A mold 300 for the post cap block 24 is shown in Figure 14. The post cap block 24 preferably includes non-textured portions. Consequently, all surfaces of the post cap block 24 are faced by the mold 300 or portions of the mold 302.

A straight wall

[0104] Figure 15A shows a straight wall portion formed by a set of angle blocks 10. In such a straight wall portion or bottom row of angle blocks 10, the relatively short first face 38 of a building block 10 faces the relatively long face 40 of an adjacent block, which in turn faces the relatively short first face 38 of another angle block 10. An upper row of angle building blocks 10 can be interlocked with the straight wall portion shown by moving the upper row of angle blocks a distance of half the length of the angle building block 10 so that the continuous interlocks 54 of the lower row of angle blocks 10 are seated in secondary cores formed by confronting secondary core portions 46, 50 of facing upper angle blocks 10.

[0105] Figure 15B shows a straight wall portion formed by tensioning blocks 14. Another straight wall portion of tensioner blocks 14 may be placed on said first straight bottom wall section, with said second or upper straight wall portion being offset a distance of one-fourth of a tensioner block from the lower straight portion of wall so that the interlocks 142, 144 of the lower straight wall tensioner blocks 14 are seated in the central core 122 and the secondary core portions 134 and 138 of the upper building blocks. Such displacement and interlocking continues with each row of tensioner blocks 14.

A curved wall

[0106] Figure 16A shows a curved upper row or wall portion formed by angle blocks 10 where the relatively short sides 38 of the angle block 10 face each other and where the relatively long sides 40 face each other. An upper row of angle blocks 10 is interlocked with the lower row by shifting the upper row a distance of half an angle block 10 so that the continuous interlocks 54 of the lower row are seated in the secondary cores formed by core portions. Secondary 46, 50 of the top row.

[0107] Figure 16B shows a curved wall portion formed by angle block 10, tensioning block 14, block 102 (field modified version of block 12) and a corner block 20 positioned upside down. It should be noted that curves of a great variety of different slopes can be formed by confronting different ends of different blocks and their versions modified in the field.

A corner

[0108] Wall corner parts, such as the wall corner part 310 shown in Figure 17A, can be formed using corner blocks 20 (which are textured on two sides and one end) with field modified block or block three rooms 192 where each of the corner block 20 and field modified block 192 are staggered when corner 310 is formed. Extending from corner 310 (or field modified corner block / block combination), there may be one or more of angle blocks 10, angle blocks 12, tensioner blocks 14, tensioner blocks 16, and tensioner blocks18 (all of which have texture on two sides). The corner blocks 20 form the end corner of the wall corner portions and the remaining blocks are attached within the corner blocks 20 with one or more interlocking devices, such as interlocks 54, 92, 142, 144, and 182. (including interlocking segments 184, 186), Posts may be inserted through aligned cores of the blocks and further into the ground to provide tip-over resistance to the wall corner portion.

A pole

[0109] Figure 17B shows a masonry post 312 by corner blocks 20. Each side of post 312 is formed by staggered layers of one side 212 of one corner block 20 and one end 206 of another corner block 20. Glue and / or tubing can be used to interlock the corner blocks 20 together. A piece of tube can extend through inner cores 231 that are aligned with each other and / or through central cores 214 and secondary core portions 230 that are aligned with each other.

[0110] Each of the masonry posts 312 includes a pair of post cap blocks 24 positioned end-to-end to form a post cap. The post cap is preferably large enough to protrude somewhat from the sides of the post.

Pipeline

[0111] As shown in Figure 18A, pipe 320, where used, as shown in Figure 18A, can be a piece of tubular steel pipes and can have an outer diameter of preferably 3.5 cm (approximately one and three-eighths of an inch). The outside diameter of the pipe is preferably slightly less than or equal to the inside diameter of the interlocks of the present invention, such as continuous interlocks 54 whereby the pipe faces all other blocks of the present invention. In

ES 2 415 768 T3 other words, the pipe runs through and faces the interlocking of a block, then immediately runs through a main core or part of a secondary core of an immediately adjacent block, then immediately runs through and faces the next block interlocking on the next level.

[0112] This pipe is easily cut with a pipe cutter in the field. Pipes may be preferred where the walls or wall portions are greater than about three to four feet in height.

Random appearances

[0113] Figure 18B shows how a wall portion of the present invention can have a random appearance. Such wall may have one or more angle blocks 10, one or more angle blocks 12 and / or their field modified versions, one or more tensioning blocks 14, one or more tensioning blocks 16 and / or their field modified versions. , one or more tensioner blocks 18 and / or their field modified versions, one or more corner blocks 20, and one or more cap blocks 22.

[0114] Furthermore, one or more of the blocks in the random appearance may have grooves 330 formed in the surface to provide the appearance of a half block when in fact the block is a complete block, such as a tension block 14. As for forming such grooving 330, see for example the following US patents: US Patent to Bott No. 6,082,067 dated July 4, 2000 entitled "Dry Stackable Block Structures" and US Pat. a Bott n ° 6,322,742 published November 27, 2001 entitled Stackable Concrete Block Production Method.

Serpentine wall

[0115] A serpentine or corrugated wall can be formed 1) by combinations of curved walls, 2) combinations of straight walls and / or 3) combinations of curved and straight wall. For example, Figure 19A shows a serpentine wall portion 340 formed by curved wall portions shown in Figure 16A. The serpentine wall portion 310 uses ten angle blocks 10 for a full wavelength, but as few as four angle blocks 10 for a full wavelength can be used for a serpentine wall portion 340. A second wavelength "of ten angle blocks 10 may be interlocked at the top of the corrugated row 340, shown in FIG. 19A, with the second wavelength" of ten angle blocks 10 being offset from the corrugated row 340 a distance of one-half the length of an angle block 10 such that the secondary core portions of the second wavelength are seated in the enervations 54 of the first wavelength.

[0116] Another type of serpentine wall is shown in Figure 19B where a zig-zag type of serpentine wall portion 350 includes a number of corners, such as corner 310 as shown in Figure 17A. Here a second wavelength can be placed on top of the wall portion 350 with the corner blocks 20 staggered as shown in Figure 17A for each of the corners 310 so that the field modified block 192 interlocks. the corners 310 to each other.

[0117] Blocks of the present invention, other than those shown in Figures 19A and 19B, may be used to form corrugated or zigzag walls

[0118] All other factors being equal, a serpentine wall has a relatively large magnitude of stability compared to a straight wall. For example, while a straight wall can be considered to have stability along only the longitudinal length of the wall, a serpentine wall has stability in both the longitudinal and lateral directions.

Wall stability

[0119] The stability of a wall formed by one or more blocks of the present invention is provided by one or more of the following characteristics: 1) the interlocking and seating characteristics of the blocks; 2) the mass of the blocks used in the wall; 3) the flatness of the upper and lower faces of the blocks, and 4) the shape of the wall, especially when constructing serpentine or zigzag or step walls: and 5) pipes as described above, They go down into the cores and burrow into the ground. Buckling-in-wall stability of blocks

[0120] Regarding the interlocking and seating characteristics, the enervations (54, 92, 94, 96, 142, 144, 182, 184, 186) of lower blocks can settle in relatively large cores (122, 214) and in the secondary cores formed by the secondary core portions (46, 50, 134, 138, 230) of the upper blocks. It should be noted that the relatively small nuclei (42, 126, 128, 218) cannot provide seats for the enervations since these relatively small nuclei are smaller in size (smaller radius or diameter) than the diameter or outer radius of the enervations. The 42, 126, 128 and 218 cores have non-interlocking cores. Cores 122, 214 have interlocking receptor or interlocking seat cores. Secondary cores have interlocking receptor or interlocking seat cores, such as due to their size or shape. The enervations cannot fit into such relatively small cores 42, 126, 128 and 218 and thus provide a warning to a wall builder that he or she has not found a proper interlocking fit. In other words, the only proper fit between adjacent blocks of different heights is the self-aligning fit of the enervations.

[0121] In other words, if, when placing one of the blocks on a lower row of blocks, the lower face of the newly placed block is flat against the upper face of the lower row, then one can be sure that it has a fit interlocking. In still other words, contiguous blocks of different height do not interlock if one attempts to seat an enervating core over an interlocking.

[0122] Stability of the wall-mass or density of the block

Regarding the mass or weight of the blocks, the density of a block is preferably between 1922 kg / m³(about 120 pounds per cubic foot) and 2243 kg / m³ (about 140 pounds per cubic foot), more preferably between 2002 and

ES 2 415 768 T3

2243 kg / m³ (about 125-140 pounds per cubic foot), and more preferably between 2082 kg / m³ (about 130 pounds per cubic foot) and 2245 kg / m³ (about 140 pounds per cubic foot). The weight of a block is preferably small enough to allow the block to be handled by the owner (eg, to be lifted into place about three or four feet off the ground by an adult female or medium strength adult male). The weight of the block is preferably as great as possible to give as much stability to the wall as possible. Flatness-to-wall stability of load-bearing face

[0123] Without taking into account the locks or interlocking segments, the upper faces (30, 110, 202) and the lower faces (32, 112, 204) of the blocks (10, 12, 14, 16, 18, 20) they are preferably as flat as possible. In other words, the upper and lower faces are preferably free of recesses or extensions except for the interlocks, cores and secondary core parts. In still other words, not taking into account the interlocks, cores or secondary core parts, the upper and lower faces are preferably 90% free of those non-planar features, more preferably 95% free of such non-planar features, and even more preferably 99% free of such non-planar features, and more preferably 99.9% or more free of such non-planar features. When considering flatness, the rough standard surface of a cinder block and the usual nicks in a cinder block surface are not taken into account. Given the standard rough surface and the usual nicks, the top and bottom faces are substantially flat, with no gaps, grooves, grooves, extensions, bumps, ribs, or any other feature that deviates from a flat surface. Such flatness provides a downward load or force that equals or extends over the entire wall, thus giving relatively great stability. Flatness also means that all points on the upper surface will be contained between two parallel planes, the base plane and the ceiling plane, separated by a distance no greater than that specified and that all points on the lower surface will be contained between two Parallel planes, the base plane and the ceiling plane, separated by a distance no greater than that specified. Such specified distance is preferably less than 0.64 cm (approx. a quarter inch), more preferably less than 0.32 cm (about one eighth of an inch), even more preferably less than 0.16 cm (about one sixteenth of an inch), and most preferably less than 0.08 cm (approx. one thirty-second of an inch). Flatness further means that the upper surface is in a plane that is parallel to a plane in which the lower surface lies.

[0124] Such blocks where flatness is maximized also provide maximum friction in lateral and longitudinal directions. This minimizes the probability that during the construction of a wall, a block will fall or slide off the wall, after which the block would break when hitting the ground.

Block composition

[0125] Each of the blocks 10, 12, 14, 16, 18, 20, 22, 24 can be formed from almost any variety of a concrete mix or fill. The mix or fill may depend on a number of factors, including the desired strength of the block, the desired water absorption, the desired density, the desired shrinkage, and other physical characteristics. A cement mix for such blocks can include one or more of cement, fly ash, water, sand, gravel, rock, plasticizers, waterproofing agents, crosslinking agents, dyes, colorants, and pigments.

Exposed surfaces of the blocks

[0126] The exposed surfaces of the blocks of the present invention, such as where the exposed surfaces are the sides 38, 40 of the angle blocks 10, 12, or the sides 118, 120 of the tensioner blocks 14, 16, 18, or the sides 210, 212 and end 206 of corner block 20 are preferably finished surfaces. A finished surface can be textured or non-textured. A finished surface can be aged or unaged. Textured finished surface is preferable. More preferred is a finished surface that is textured using the mold designs of the present invention, such as the mold designs of Figures 4, 8, or 10.

[0127] The wall construction according to the present invention provides the opportunity to have both vertical wall surfaces finished based on the shape and fit of the individual units or blocks. This feature develops the basis for a structure that is both functionally and architecturally attractive.