|
(11) | EP 4 353 920 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
|
|
|
|
|||||||||||||||||||||||||||
| (54) | INTERLOCKING HOLLOW CONCRETE BLOCK AND LOCKING BLOCK |
| (57) An interlocking hollow concrete block (10) having two parallel long side walls (14)
and two parallel short side walls (12) defining a hollow rectangular shape. Each of
the two long side walls (14) and each of the two short side walls (12) have protrusions
(20) on the top surface (16) and cavities (30) on the bottom surface (18). The protrusions
(20) are identical in the width direction and the depth direction, and the protrusions
(20) are tapered in the height direction. Each of the cavities (30) is configured
to accommodate a protrusion (20) of a similar concrete block (10). The concrete block
is further defined in that each of the long side walls (14) and the two short side
walls (12) form an obtuse angle with the top surface (16) and each of the two long
side walls (14) and the two short side walls (12) forms an acute angle with the bottom
surface (18).
|
FIELD OF THE INVENTION
[0001] The invention relates to concrete building blocks and/or to a locking block holding other blocks in place.
PRIOR ART
[0002] Concrete blocks are widely used for construction of houses and support structures, such as foundations or retaining walls. The concrete blocks are typically laid like bricks using mortar in between the blocks. Often rebars are installed in grooves or hollow cores of the blocks to hold the blocks together with mortar or poured concrete.
[0003] There are also concrete blocks having a tongue and groove type of joint that prevents movement in one direction without using mortar. These types of concrete blocks are often used in building of retaining walls of low height where the joint prevents lateral earth pressure from moving the concrete blocks of the retaining wall.
[0004] A problem with the prior art concrete blocks is that each block is designed for a single purpose and often mortar is required for keeping the blocks together. These features are problematic for not only using the blocks but also from reusing perspective.
BRIEF DESCRIPTION OF THE INVENTION
[0005] The object of the invention is a concrete block which alleviates the drawbacks of the prior art.
[0006] Object of the invention is achieved with an interlocking hollow concrete block according to claim 1. The concrete block interlocks with other similar blocks above and below with the protrusions and cavities. Placement of the protrusions and cavities allows for a large number of interlocking positions between two blocks.
BRIEF DESCRIPTION OF THE FIGURES
[0007] The invention is now described in more detail in connection with preferred embodiments, with reference to the accompanying drawings, in which:
Fig. 1 is an isometric illustration of a concrete block according to an embodiment;
Fig. 2 is an isometric illustration of a concrete block according to an embodiment;
Fig. 3 shows a top view of a concrete block according to an embodiment;
Fig. 4 shows a side view of a concrete block according to an embodiment;
Fig. 5 illustrates a plurality of concrete blocks according to an embodiment forming a structure having right angle;
Fig. 6 illustrates a plurality of concrete blocks according to an embodiment forming a structure having T-junction;
Fig. 7 is an isometric illustration of a cover block according to an embodiment;
Fig. 8 is an isometric illustration of a rim block according to an embodiment;
Fig. 9a-d illustrates assembling of a structure according to an embodiment;
Fig. 10 illustrates a set of structures built using concrete blocks according to an embodiment;
Fig. 11 illustrates stairs built using concrete blocks according to an embodiment;
Fig. 12 shows a top view of some interlocking positions of two concrete blocks according to an embodiment;
Fig. 13 shows a top view of some other interlocking positions of two concrete blocks according to an embodiment;
Fig. 14 illustrates a cross-section in plane x-y through the middle of a concrete block according to an embodiment;
Fig. 15 illustrates a cross-section in plane z-y through the middle of a concrete block according to an embodiment;
Fig. 16 is an isometric illustration of a locking block according to an embodiment;
Fig. 17 illustrates a cross-section in plane x-y through the middle of a concrete block with a locking block inside it;
Fig. 18 illustrates a cross-section in plane x-y through the middle of a retaining wall built from concrete blocks according to an embodiment and locked with a locking block according to an embodiment;
Fig. 19 shows a detail of Figure 18;
Fig. 20 illustrates a cross-section in plane z-y through the middle of a solid block according to an embodiment;
Fig. 21 illustrates a cross-section in plane x-y through the middle of a solid block according to an embodiment;
Fig. 22 is an isometric illustration showing the top surface of a solid cover block according to an embodiment;
Fig. 23 is an isometric illustration showing the bottom surface of a solid cover block according to an embodiment;
Fig. 24 illustrates a cross-section in plane x-y through the middle of a retaining wall built from various blocks and locked with a locking block according to an embodiment;
Fig. 25 shows a top view of a square concrete block according to an embodiment;
Fig. 26 is an isometric illustration of a square concrete block according to an embodiment;
Fig. 27 is an isometric illustration of an exemplary fence built with solid blocks and square concrete blocks;
Fig. 28 shows a top view of a right-hand curve block according to an embodiment;
Fig. 29 is an isometric illustration of a right-hand curve block according to an embodiment;
Fig. 30 shows a top view of a left-hand curve block according to an embodiment;
Fig. 31 is an isometric illustration of a left-hand curve block according to an embodiment;
Fig. 32 shows a top view of a circular block according to an embodiment;
Fig. 33 is an isometric illustration of a circular block according to an embodiment;
Fig. 34 shows a top view of a long concrete block according to an embodiment;
Fig. 35 shows a top view of a short concrete block according to an embodiment;
Fig. 36 shows a top view of a partially hollow concrete block according to an embodiment; and
Fig. 37 shows a top view of a corner block according to an embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0008] Figures 1 to 4 show an embodiment of an interlocking hollow concrete block from different viewing angles. The concrete blocks and any other blocks of the present disclosure can be made by pouring concrete to a mould. All the blocks can also be manufactured with on a concrete block production line in wet casting or dry casting process. Basically, any type of special concrete can be used, in addition to normal concrete based on Portland cement. For example, foam concrete such as lightweight cellular concrete or low-density cellular concrete can be used as well as geopolymer concrete and fully or partially recycled concrete. Sizing of the concrete block and wall thickness can be varied based on requirements or objectives.
[0009] The interlocking hollow concrete block 10 has two parallel long side walls 14 which extend in a width direction, denoted with 'x' in upper left corner of Fig. 1. The block has also two parallel short side walls 12 which extend in a depth direction, denoted with 'z' in upper left corner of Fig. 1. The depth direction (z) perpendicular to the width direction (x). To be exact, outer surfaces of the two long side walls are parallel and outer surfaces of the two short side walls are parallel. The two short side walls 12 and the two long side walls 14 define a hollow rectangular shape. The short side walls connect at their ends to ends of the long side walls so that a hollow core 50 is formed between the walls. The word 'hollow' in interlocking hollow concrete blocks refers to said hollow core 50. The hollow core is a single, continuous, hollow space within the block which hollow core is not divided into smaller hollow spaces.
[0010] Each of the two long side walls 14 and the two short side walls 12 are delimited in a height direction (y) by a top surface 16 in a first plane and a bottom surface 18 in a second plane parallel to the first plane. The top surface 16 and the bottom surface are thus parallel surfaces. The height direction, denoted with 'y' in upper left corner of Fig. 1, is parallel to a normal of the first plane, and the height direction is perpendicular to both the width direction (x) and the depth direction (z).
[0011] Figures 14 and 15 illustrate cross-sections in plane x-y and plane z-y, respectively, through the middle of a concrete block according to an embodiment. These Figures 14 and 15 show that each of the two long side walls 14 and the two short side walls 12 taper in height direction. Outer surfaces extending in the height direction of each of the two long side walls 14 and the two short side walls 12 are perpendicular to both the top surface 16 and the bottom surface 18. Inner surfaces extending in the height direction of each of the two long side walls 14 and the two short side walls 12 are thicker at the bottom surface 18 level than at the top surface 16 level. Therefore, the top surface 116 has a smaller surface area than the bottom surface 118.
[0012] The inner walls of the long side walls and the short side walls are thus not perpendicular to neither the top surface 16 nor the bottom surface 18. Preferably the inner walls of the long side walls and the short side walls differ from 1° to 15° from a direction perpendicular to the top surface 16 and the bottom surface 18. The hollow core 50 is thus a wedge-shaped hollow space within the two long side walls and the two short side walls. Each of the long side walls 14 and the short side walls 12 of the block 10 forms an obtuse angle with the top surface 16. Similarly, each of the long side walls 14 and the short side walls 12 of the block 10 forms an acute angle with the bottom surface 18. An interlocking feature of the blocks is achieved by each of the two long side walls 14 and each of the two short side walls 12 having protrusions 20 on the top surface 16 and cavities 30 on the bottom surface 18. The protrusions 20 and the cavities 30 are preferably essentially similarly shaped and sized with the exception of the cavities being slightly larger than the protrusions to ensure that the protrusions of a concrete block fit completely inside the cavities of another concrete block. Each of the cavities 30 is configured to accommodate a protrusion 20 of a similar concrete block 10. In an embodiment, the cavities 30 have a shape of a truncated cone and the protrusions 20 have a shape of a spherical cap.
[0013] The protrusions 20 are identical in the width direction and the depth direction which means that the protrusions look the same whether those are viewed from the width direction (x) or the depth direction (z). The protrusions are tapered in the height direction. Tapering means that diameter or circumference of the protrusion is smaller further away from the top surface 18 than closer to the top surface. The tapering facilitates manufacturing of the blocks and easier fitting with adjacent blocks beneath. The cavities 30 can also be tapered for a tight fit but it is not necessary. Similarly, the cavities 30 can be identical in the width direction and the depth direction - just like the protrusions 20 - but it is not necessary.
[0014] In an embodiment, each of the two long side walls 14 of the interlocking hollow concrete block 10 comprises three or more protrusions 20 on the top surface 16 and three or more cavities 30 on the bottom surface 18. Each of the two short side walls 12 comprises two or more protrusions 20 on the top surface 16 and two or more cavities 30 on the bottom surface 30. In the embodiment of Figures 1 to 4 illustrate an interlocking hollow concrete block 10 with three protrusions and cavities on each long side wall and two protrusions and cavities on each short side wall. The protrusions in Figures 1, 3 and 4 have a circular cross-section in the first plane and the protrusions 20 are tapered. The protrusions in those embodiments have a shape of a spherical cap or a hemi-sphere. The protrusions in Figures 5 and 6 have a circular cross-section in the first plane and the protrusions are slightly tapered. The protrusions 20 of those embodiments have a shape of a truncated cone. As shown in the Figures, the protrusions are preferably rotationally symmetrical in a plane parallel to the first plane.
[0015] In a preferred embodiment, each of the two long side walls 14 of the interlocking hollow concrete block 10 comprises three protrusions 20 on the top surface 16 and three cavities 30 on the bottom surface 18. Each of the two short side walls 12 comprises two protrusions 20 on the top surface 16 and two cavities 30 on the bottom surface 30. A spacing of the protrusions of each of the short side walls 12 is equal to the spacing of the protrusions of each of the long side walls 14. The spacing is the distance between centres of two adjacent protrusions on a given side wall. Thus, in this case, the distance between the two protrusions on either one of the short side walls 12 is the same as the distance from a protrusion in middle of either one of the long side walls to either one of the other two protrusions on that same long side wall.
[0016] In an embodiment which may or may not be the previous preferred embodiment, a distance between any protrusion 20 of the short side walls 12 and the nearest corner of the concrete block 10 is equal to the distance between the outermost protrusions 20 of the long side walls and the nearest corner of the concrete block 10. In other words, regardless of which side wall is being viewed, the protrusion that is closest to a corner of the concrete block 10 is always at the same specific distance from the corner.
[0017] In an embodiment which may or may not be the previously described embodiment, the spacing of the protrusions of each of the short side walls 12 and each of the long side walls 14 is twice the distance between any protrusion 20 of the short side walls 12 and the nearest edge of the concrete block 10 measured along a line passing through centres of the protrusions 20 of that short side wall 12. This placing of the protrusions allows for continuous even spacing of protrusions of concrete blocks laid next to each other.
[0018] The continuous spacing of plurality of concrete blocks can be seen from Figure 5, in which a plurality of concrete blocks 10 form a structure 90 having right angle. By looking at the concrete blocks on the top, the spacing of the protrusions is the same within a block and between two blocks. Even on the outside corner of the structure where two adjacent concrete blocks have different orientations, the spacing of the protrusions on the outer edge of the structure is constant.
[0019] Figure 6 shows how structure 92 having a T-junction can be done with concrete blocks of this type. The placing of the protrusions once again helps to build the interlocked structure 92 with each concrete block interlocking with at least two other concrete blocks in the row of concrete blocks below.
[0020] When building load-bearing walls, foundations or retaining walls in demanding conditions, there may arise a need for added rigidity or insulation. In an embodiment, a structure comprises a plurality of the interlocking hollow concrete blocks 10 of the present disclosure. Said concrete blocks are interlocked within the structure and hollow centres 50 of said concrete blocks are at least partially filled with reinforced concrete. In another embodiment, the hollow centres 50 of said concrete blocks 10 is at least partially filled with polyurethane foam.
[0021] Referring now to Figures 12 and 13 which illustrate the vast number of possibilities for interlocking placement of two concrete blocks 10 of an embodiment. The terms interlocking and interlocking placement mean that two interlocked blocks cannot be moved nor rotated in relation to each other in depth (z) or width (x) direction. This is achieved by having at least two protrusions 20 of one block being accommodated by the same number of cavities 30 of the other block on top.
[0022] The interlocking hollow concrete block of the embodiments in Figures 12 and 13 has three protrusions on each of the two long side walls 14 and two protrusions on each of the short side walls 12. The protrusions have a shape of a spherical cap, such as a hemi-sphere, or a shape of a truncated cone. The spacing of the protrusions of the short side walls 12 is equal to the spacing of the protrusions of the long side walls 14. The spacing is also twice the distance between any protrusion 20 of the short side walls 12 and the nearest edge of the concrete block 10 measured along a line passing through centres of the protrusions 20 of that short side wall 12. For each protrusion 20 on the top surface 16, the concrete blocks have corresponding cavities 30 in the bottom surface directly beneath the protrusions 20 in height direction (y).
[0023] Figure 12 shows two interlocked concrete blocks 10 on top of each other in 28 different positions relative to each other, where at least two protrusions of one block are accommodated by the same number of cavities of the other block. The blocks drawn with a solid line are on top of the blocks drawn with a dashed line. That is, the blocks drawn with the solid line are on a higher level in height direction than the blocks drawn with the dashed line. Figure 12 only shows combinations where both of the blocks have the same orientation and one of the blocks is partially on top of the other block. A position where the two blocks are directly on top of each other is not shown in Figure 12.
[0024] Figure 13 shows two interlocked concrete blocks 10 on top of each other in 38 different positions relative to each other, where at least two protrusions of one block are accommodated by the same number of cavities of the other block. The blocks drawn with a solid line are on top of the blocks drawn with a dashed line. That is, the blocks drawn with the solid line are on a higher level in height direction than the blocks drawn with the dashed line. Figure 13 only shows combinations where one of the blocks has been rotated 90° relative to the other block and one of the blocks is partially on top of the other block. A position where the two blocks are directly on top of each other is not possible with this orientation of the concrete blocks.
[0025] In an embodiment, the protrusions 20 on the top surface 16 and the cavities 30 on the bottoms surface 18 are arranged in a formation which allows for placement of the concrete block 10 partially on top of a similar second concrete block 10 at least 50 different positions where at least two protrusions of the concrete block are accommodated by cavities 30 of the second concrete block 10 in each of the at least 50 positions. More preferably the number of such positions is at least 66, which is the combined number of positions shown in Figures 12 and 13.
[0026] Figure 7 is an isometric illustration of a cover block 60 according to an embodiment. The cover block is preferably a rectangular interlocking block that can be made out of concrete, wood, plastics or practically any preferred material. The cover block 60 is interlocking with the interlocking hollow concrete block 10 shown in e.g. Figures 1 to 4 so the cover block also has cavities on its bottom surface for accommodating protrusions of a concrete block 10. However, the cover block 60 is mostly flat and solid unlike the hollow concrete block 10. The cover block 60 has a relatively large, and preferably flat, top surface 66 which may have a tapered or bevelled edge 65 to two short sides 62 and two long sides 64.
[0027] Fig. 8 is an isometric illustration of a rim block 70 according to an embodiment. The rim block 70 is preferably a rectangular interlocking hollow block that can be made out of concrete, wood, plastics or practically any preferred material. The rim block 70 has a hollow core 71 and the rim block is interlocking with the interlocking hollow concrete block 10 shown in e.g. Figures 1 to 4. The rim block has cavities on its bottom surface for accommodating protrusions of a concrete block 10. The rim block 70 has two short side walls 72 and two long side walls 74 but it has much smaller height than the concrete block 10 and the rim block does not have protrusion on its top surface 76.
[0028] Figures 9a to 9d illustrate step-by-step how a structure 90 is constructed using three interlocking hollow concrete blocks 10 and one rim block 70. Starting from Fig. 9a, a first concrete block 10 is placed on a level surface. In Fig. 9b a second concrete block 10 is placed directly on top of the first concrete block. In Fig. 9c one more concrete block is added and in Fig. 9d a rim block 70 is placed on top of the three concrete blocks 10. The structure 90 in Fig. 9d is extremely simple to build as there is no need to use mortar and it only consists of four parts. When the structure is no longer needed, it can be disassembled just as easily and the blocks can be used elsewhere. This type of structure 90 could be used as a storage or it could be filled with soil into which flowers could be planted or seeds could be sown.
[0029] Figure 10 shows further examples of structures that can be built with the concrete blocks 10. In addition to the structure 90 of Fig. 9d, there are two benches 92, each made with two interlocking hollow concrete blocks 10 on top of each other and a cover block 60 on top. In a similar way, a table 91 is built with four interlocking hollow concrete blocks 10 on top of each other and a cover block 60 on top.
[0030] Figure 11 shows yet another structure that can be built with the concrete blocks 10. Stairs can be built with a desired number of interlocking hollow concrete blocks 10 partially on top of each other. In the case of Figure 11, a step of stairs is overlapping 50 % of the previous step. The highest step can be covered with a cover block 60 whereas for the other steps, a cover block has to be cut in half to result a half-cover block 61. If the stairs were to be freestanding, the required support structures could also be made with the concrete blocks.
[0031] Figure 16 illustrates a locking block 100 according to an embodiment. The locking blocks 100 can be made by pouring concrete to a mould or on a concrete block production line. Basically, any type of special concrete can be used, in addition to normal concrete based on Portland cement. For example, foam concrete such as lightweight cellular concrete or low-density cellular concrete can be used as well as geopolymer concrete and fully or partially recycled concrete.
[0032] The locking block 100 has a top surface 116 and a bottom surface 118 which are parallel with each other. The top surface 116 has a larger surface area than the bottom surface 118. The locking block 100 has two long side walls 114 and two short side walls 112. The long side walls 114 and the short side walls 112 are not perpendicular to the top surface 116 nor the bottom surface 118. Each of the long side walls 114 and the short side walls 112 of the locking block 100 forms an acute angle with the top surface 116. Similarly, each of the long side walls 114 and the short side walls 112 of the locking block 100 forms an obtuse angle with the bottom surface 118. The locking block 100 thus a shape of a truncated wedge tapering from all sides towards the bottom surface 118. The locking block 100 preferably has one or more through holes or tubes 110 extending from the top surface 116 to the bottom surface 118. Said through holes or tubes are perpendicular to both the top surface 116 and the bottom surface 118.
[0033] Figure 17 illustrates a cross-section in plane x-y through the middle of an interlocking hollow concrete block 10 with a locking block 100 inside it. As the name implies, the locking block 100 is intended to lock in place inside the interlocking hollow concrete block 10. This is achieved by the wedge shape of both the locking block 100 and the hollow core 50 of the interlocking hollow concrete block. Preferably each side wall 112, 114 of the locking block 100 has a parallel inner surface of a side wall 12, 14 in an interlocking hollow concrete block 10 of the present disclosure when the top surface 116 of the locking block 100 is parallel to the top surface 16 of said interlocking hollow concrete block 10. The top surface 116 of the locking block has a surface area that is larger than the surface area of the hollow core 50 of the interlocking hollow concrete block 10 at the plane of the bottom surface 18 of the interlocking hollow concrete block 10 but smaller than the surface area of the hollow core 50 of the interlocking hollow concrete block 10 at the plane of the top surface 18 of the interlocking hollow concrete block 10. A perpendicular distance between the top surface 116 of the locking block and the bottom surface 118 of the locking block is smaller than a perpendicular distance between the top surface 16 of the interlocking hollow concrete block 10 and the bottom surface 18 of the interlocking hollow concrete block. In practice, the locking block 100 can be inserted from the top inside the interlocking hollow concrete block 10 so that the locking block 100 is completely inside the hollow core 50 of the interlocking hollow concrete block 10. The locking block 100 can only be removed from inside the interlocking hollow concrete block 10 by lifting the locking block 100 straight upwards.
[0034] Figure 18 shows a use example for the different blocks of the present disclosure. Figure 18 illustrates a cross-section in plane x-y through the middle of a retaining wall built from interlocking hollow concrete blocks 10 according to an embodiment and locked with a locking block 100 according to an embodiment. Figure 19 shows a detail of Figure 18. The retaining wall of Figure 18 is built on a foundation 150 which is preferably concrete slab casted on site. One or more threaded rods 120 are fixed to the foundation in vertical position extending upwards from the foundation. Total of six layers of interlocking hollow concrete blocks 10 have been placed on the foundation to form the retaining wall. A locking block 100 has been placed inside of the interlocking hollow concrete blocks 10 of the topmost layer in such a way that the one or more threaded rods 120, in this example three threaded rods, run through the tubes 110 of the locking block 100. Figure 19 shows how the locking block is tightened against the interlocking hollow concrete block 10. A nut 122 on the threaded rod 120 is tightened which firmly pushes the locking block 100 downwards and against the interlocking hollow concrete block 10. A washer 123 is preferably used between the locking block 100 and the nut 122. When the nut 122 is tightened, it prevents the locking block from moving and it also prevents all the interlocking hollow concrete blocks below it from moving. Ultimately, the tightened locking block 100 prevents the retaining wall from tilting. The locking block can be used in each of the interlocking hollow concrete blocks in the topmost layer of the retaining wall or just in some of the interlocking hollow concrete blocks of the topmost layer. The locking blocks can also be used in lower layers as well. The locking blocks can also be used in other construction than retaining walls. The locking blocks add weight to a structure and even without threaded rods or tightening, the locking blocks increase stability of a structure, especially when used in lower layers to lower the mass center of the structure.
[0035] Figure 20 illustrates a cross-section in plane z-y through the middle of a solid block 200 according to an embodiment and Figure 21 illustrates a cross-section in plane x-y through the middle of a solid block 200 according to an embodiment. Figure 20 and Figure 21 can illustrate the same solid block or two different types of solid blocks. The solid block 200 has two parallel long sides 214 which extend in a width direction, denoted with 'x' in upper left corner of Fig. 21. The solid block has also two parallel short sides 212 which extend in a depth direction, denoted with 'z' in upper left corner of Fig. 20. The depth direction (z) perpendicular to the width direction (x). To be exact, the two long sides are parallel and the two short sides are parallel. The two short sides 212 and the two long sides 214 define a solid rectangular shape. The solid block 200 can have either zero or one or more through holes or tubes 110 extending between the top surface 16 and the bottom surface 218 of the solid block 200. The solid block 200 can be used as a first layer in various structures to lower the mass center of a structure. The structure can be attached to a foundation by fixing one or more threaded rods into the foundation so that the one or more threaded rods run through the tubes 110 or through holes of the solid block. The solid block can then be clamped against the foundation by using washers and nuts on the threaded rods.
[0036] Each of the two long sides 214 and the two short sides 212 of the solid block 200 are delimited in a height direction (y) by a top surface 216 in a first plane and a bottom surface 218 in a second plane parallel to the first plane. The top surface 216 and the bottom surface are thus parallel surfaces. The height direction, denoted with `y' in upper left corner of Figures 20 and 21, is parallel to a normal of the first plane, and the height direction is perpendicular to both the width direction (x) and the depth direction (z).
[0037] An interlocking feature of the solid blocks 200 is achieved by the top surface 216 having protrusions 20 along each of the two long sides 214 and each of the two short sides 212, and cavities 30 on the bottom surface 218 directly below the protrusions in the height direction (y). The protrusions 20 and the cavities 30 are preferably essentially similarly shaped and sized with the exception of the cavities being slightly larger than the protrusions to ensure that the protrusions of a block fit completely inside the cavities of another block. Each of the cavities 30 is configured to accommodate a protrusion 20 of a similar solid block 210 and preferably configured to accommodate a protrusion 20 of any block of the present disclosure. The protrusions 20 are identical in the width direction and the depth direction and the protrusions 20 are tapered in the height direction. Preferably the cavities 30 are identical in the width direction and the depth direction. In an embodiment, the cavities 30 are tapered in the height direction. In an embodiment, the cavities 30 have a shape of a truncated cone and the protrusions 20 have a shape of a spherical cap.
[0038] Figure 22 is an isometric illustration showing the top surface of a solid cover block 210 according to an embodiment and Figure 23 is an isometric illustration showing the bottom surface of a solid cover block 210 according to an embodiment. Figure 22 and Figure 23 can illustrate the same solid cover block or two different types of solid cover blocks. The solid cover block 210 has two parallel long sides 214 which extend in a width direction, denoted with 'x' in upper left corner of Figures 22 and 23. The solid cover block has also two parallel short sides 212 which extend in a depth direction, denoted with 'z' in upper left corner of Figures 22 and 23. The depth direction (z) perpendicular to the width direction (x). To be exact, the two long sides are parallel and the two short sides are parallel. The two short sides 212 and the two long sides 214 define a solid rectangular shape. The solid cover block 210 can have either zero or one or more through holes or tubes extending between the top surface 216 and the bottom surface 218 of the solid cover block 210. The solid cover block 210 can be used as the topmost layer in various structures for a smooth finish since the solid cover block does not have protrusions on the top surface 216 nor a hollow core. The structure can be attached to a foundation by fixing one or more threaded rods into the foundation so that the one or more threaded rods run through tubes or through holes of the solid cover block. The solid cover block can then clamp any blocks between the solid cover block 210 and the foundation by using washers and nuts on the threaded rods.
[0039] Each of the two long sides 214 and the two short sides 212 of the solid cover block 210 are delimited in a height direction (y) by a top surface 216 in a first plane and a bottom surface 218 in a second plane parallel to the first plane. The top surface 216 and the bottom surface 218 are thus parallel surfaces. The height direction, denoted with `y' in upper left corner of Figures 22 and 23, is parallel to a normal of the first plane, and the height direction is perpendicular to both the width direction (x) and the depth direction (z).
[0040] An interlocking feature of the solid cover blocks 210 is achieved by the bottom surface 218 having cavities 30 along each of the two long sides 214 and each of the two short sides 212. The slid cover blocks are intended to be used as a cover and preferably there are no protrusions on the top surface. Thus, the solid cover block only interlock with blocks underneath the solid cover block. The cavities 30 are preferably essentially similarly positioned, shaped and sized as the cavities 30 of other blocks of the present disclosure. Preferably each of the cavities 30 is configured to accommodate a protrusion 20 of any block of the present disclosure. Preferably the cavities 30 are identical in the width direction and the depth direction. In an embodiment, the cavities 30 are tapered in the height direction. In an embodiment, the cavities 30 have a shape of a truncated cone.
[0041] Fig. 24 illustrates a cross-section in plane x-y through the middle of a retaining wall built from various blocks and locked with a locking block according to an embodiment. Figure 24 illustrates a retaining wall built from interlocking hollow concrete blocks 10, solid blocks 200 and solid cover blocks 210 according to embodiments of the present disclosure. Blocks of the retaining walls are locked with a locking block 100 according to an embodiment of the present disclosure. The retaining wall of Figure 24 is built on a foundation 150 which is preferably concrete slab casted on site. One or more threaded rods 120 are fixed to the foundation in a vertical position extending upwards from the foundation. The first layer on top of the foundation 150 consists of solid blocks 200, each having three tubes 110. The next five layers on top of the layer of solid blocks 200 are interlocking hollow concrete blocks 10. The topmost layer consists of solid cover blocks 210. Locking blocks 100 have been placed inside of the interlocking hollow concrete blocks 10 of the third and sixth layer from the bottom. Three threaded rods 120 run through the tubes 110 of a solid block 200, i.e. the first layer, placed on the foundation 150 and then through the locking blocks 100 of the third and sixth layers of blocks. Preferably, one or more solid blocks are clamped against the foundation by using washers 123 and nuts 122 on the threaded rods and tightening them against the top surface of the one or more solid blocks 200. In this example, the threaded rods 120 are cut below the bottom surface of the topmost layer because the topmost layer consists of solid cover blocks 210 without tubes for the threaded rods to pass through. Protrusions on the top surfaces of the interlocking hollow concrete blocks 10 of the penultimate layer protrude into cavities of the solid cover blocks of the topmost layer. The blocks of the topmost layer remain in place due to the weight of the blocks but also some adhesive can be used between the two topmost layers to prevent anyone from disassembling the structure. An alternative would be to use solid cover blocks with tubes so that the threaded rods would reach above the top surface of the solid cover blocks where the whole structure could be locked with washers and nuts on the threaded rods.
[0042] The locking blocks 100 can be used in various ways. In Figure 24, the upper locking block 100 is tightened against an interlocking hollow concrete block 10 on the sixth layer of blocks from the bottom. A nut 122 on the threaded rod 120 is tightened which firmly pushes the locking block 100 downwards and against the interlocking hollow concrete block 10. A washer 123 is preferably used between the locking block 100 and the nut 122. When the nut 122 is tightened, it prevents the locking block from moving and it also prevents all the interlocking hollow concrete blocks below it from moving. Ultimately, the tightened locking block 100 prevents the retaining wall from tilting. The locking block can be used in each of the interlocking hollow concrete blocks in the topmost layer interlocking hollow concrete blocks of the retaining wall or just in some of the interlocking hollow concrete blocks of the topmost layer of interlocking hollow concrete blocks. The locking blocks can also be used in lower layers as well as shown in Figure 24, third layer of blocks from the bottom. In the third layer, there are washer 123 on both sides of the locking block 100 and nuts 122 tightened against the washers so that the locking block is prevented from moving in vertical direction. This way, the pressure exerted on the interlocking hollow concrete block 10 by the locking block 100 can be adjusted. This use of the locking block stabilizes both the structure and the threaded rods but prevents an excessive pressure from breaking the blocks, for example in case wet blocks repeatedly freeze and melt. The locking blocks can also be used in other construction than retaining walls. The locking blocks add weight to a structure and even without threaded rods or tightening, the locking blocks increase stability of a structure, especially when used in lower layers to lower the mass center of the structure.
[0043] Figure 25 shows a top view of a square concrete block 220 according to an embodiment and Figure 26 is an isometric illustration of a square concrete block 220 according to an embodiment. The square concrete block 220 has two parallel side walls 13x which extend in a width direction, denoted with 'x' in upper left corner of Fig. 26. The block has also two parallel side walls 13z which extend in a depth direction, denoted with 'z' in upper left corner of Fig. 26. The depth direction (z) perpendicular to the width direction (x). To be exact, outer surfaces of the two x-direction side walls 13x are parallel and outer surfaces of the two z-direction side walls 13z are parallel. The x-direction side walls 13x and the two z-direction side walls 13z define a hollow square shape. The x-direction side walls connect at their ends to ends of the z-direction side walls so that a hollow core 50 is formed between the side walls. The hollow core is a single, continuous, hollow space within the block which hollow core is not divided into smaller hollow spaces.
[0044] Each of the two x-direction side walls 13x and the two z-direction side walls 13z are delimited in a height direction (y) by a top surface 16 in a first plane and a bottom surface 18 in a second plane parallel to the first plane. The top surface 16 and the bottom surface are thus parallel surfaces. The height direction, denoted with `y' in upper left corner of Fig. 26, is parallel to a normal of the first plane, and the height direction is perpendicular to both the width direction (x) and the depth direction (z).
[0045] Preferably each of the two x-direction long side walls 13x and the two z-direction side walls 13z taper in height direction. Outer surfaces extending in the height direction of each of the two x-direction side walls 13x and the two z-direction side walls 13z are perpendicular to both the top surface 16 and the bottom surface 18. Inner surfaces extending in the height direction of each of the two x-direction side walls 13x and the two z-direction side walls 13z are thicker at the bottom surface 18 level than at the top surface 16 level. Therefore, the top surface 116 has a smaller surface area than the bottom surface 118 and the inner surfaces of the sidewalls 13x, 13z are in a non-parallel angle with the outer surfaces of said sidewalls 13x, 13z.
[0046] The inner walls of the x-direction side walls and the z-direction side walls are thus not perpendicular to neither the top surface 16 nor the bottom surface 18. Preferably the inner walls of all the side walls differ from 1° to 15° from a direction perpendicular to the top surface 16 and the bottom surface 18. The hollow core 50 is thus a wedge-shaped hollow space within all the side walls 13x, 13z. Each of the x-direction side walls 13x and the z-direction side walls 13z of the square concrete block 220 forms an obtuse angle with the top surface 16. Similarly, each of the x-direction side walls 13x and the z-direction side walls 13z of the square concrete block 220 forms an acute angle with the bottom surface 18. An interlocking feature of the square concrete blocks is achieved by each of the two x-direction side walls 13x and each of the two z-direction side walls 13z having protrusions 20 on the top surface 16 and cavities (not shown) on the bottom surface 18, directly below the protrusions in height direction (y). The protrusions 20 and the cavities are preferably essentially similarly shaped and sized with the exception of the cavities being slightly larger than the protrusions to ensure that the protrusions of a concrete block fit completely inside the cavities of another square concrete block. Each of the cavities is configured to accommodate a protrusion 20 of a similar square concrete block 220. Preferably each of the cavities of the square concrete block 220 is configured to accommodate a protrusion 20 of any block of the present disclosure. In an embodiment, the cavities have a shape of a truncated cone and the protrusions 20 have a shape of a spherical cap.
[0047] The protrusions 20 are identical in the width direction and the depth direction which means that the protrusions look the same whether those are viewed from the width direction (x) or the depth direction (z). The protrusions are tapered in the height direction. Tapering means that diameter or circumference of the protrusion is smaller further away from the top surface 18 than closer to the top surface. The tapering facilitates manufacturing of the blocks and easier fitting with adjacent blocks beneath. The cavities can also be tapered for a tight fit but it is not necessary. Similarly, the cavities can be identical in the width direction and the depth direction - just like the protrusions 20 - but it is not necessary.
[0048] In an embodiment, each of the two x-direction side walls 13x of the square concrete block 220 comprises two or more protrusions 20 on the top surface 16 and two or more cavities on the bottom surface 18. Each of the two z-direction side walls 13z comprises two or more protrusions 20 on the top surface 16 and two or more cavities 30 on the bottom surface. Preferably the number of protrusions and cavities is equal on each of the side walls of the square concrete block 220. In the embodiments of Figures 25 and 26 a square concrete block 220 with two protrusions and cavities on each side wall is illustrated. The protrusions in Figures 25 and 26 have a circular cross-section in the first plane and the protrusions 20 are tapered. The protrusions in those embodiments have a shape of a spherical cap or a hemi-sphere. As shown in the Figures, the protrusions are preferably rotationally symmetrical in a plane parallel to the first plane. A spacing of the protrusions of each of the two x-direction side walls 13x is equal to the spacing of the protrusions of each of the z-direction side walls 13z. The spacing is the distance between centres of two adjacent protrusions on a given side wall. Thus, in this case, the distance between the two protrusions on either one of the x-direction side walls 13x is the same as the distance between the two protrusions on either one of the z-direction side walls.
[0049] In an embodiment which may or may not be the previous preferred embodiment, a distance between any protrusion 20 of the x-direction side walls 13x and the nearest corner of the square concrete block 220 is equal to the distance between the outermost protrusions 20 of the z-direction side walls 13z and the nearest corner of the square concrete block 220. In other words, regardless of which side wall is being viewed, the protrusion that is closest to a corner of the square concrete block 220 is always at the same specific distance from the corner.
[0050] The square concrete block 220 can also be used with a locking block 100, similar to what is shown in e.g. Figures 16-18. Of course, the locking block 100 for the square concrete block would have to be of a different shape to what is shown in Figure 16, for example. The principles described in connection with Figures 16 and 17 can be used to design a locking block 100 for the square concrete block.
[0051] Figure 27 is an isometric illustration of an exemplary fence structure built with solid blocks 200 and square concrete blocks 220. The structure of Figure 27 can be built on a concrete foundation or on a level ground. The first layer of blocks consists of solid blocks 200 without tubes or through holes. On top of the first layer are pillars that consist of square concrete blocks 220 placed directly on top of one another. Each of these pillars consists of five square concrete blocks 220 and the pillars have a spacing of three solid blocks between the center points of the pillars. Obviously, other pillar heights and spacings can be freely chosen. Horizontally extending fence elements 225 are fixed between two adjacent pillars as shown in Figure 27with a dashed line. The fence elements could also include vertical elements but simple metal tubes or wooden poles are shown in this example. In case a more robust fence structure is desired, the hollow cores of the square concrete blocks 220 could be filled with concrete. Before the concrete is cast, rebars could be fixed from inside the hollow cores of the square concrete blocks 220 to the solid blocks directly beneath the square concrete blocks to ensure a permanent attachment between the two different types of blocks.
[0052] In general, Figure 28 to 37 illustrate various interlocking concrete blocks of different shapes. All of those blocks follow the teachings of the interlocking hollow concrete block 10 and square concrete block 220 of the present disclosure. All of the blocks can be used with a locking block 100 by following the teachings given in connection with description of Figures 16 and 17 for dimensioning the locking block. All of the blocks can be made as solid blocks 200 without or with tubes or through holes as shown in Figures 20 and 21. All of the blocks can be made as solid cover blocks 210 with tubes or through holes or without them as shown in Figures 22 and 23. Thus, these embodiments are only briefly described herein and reference is made to descriptions of Figures 1-4, 14-17 and 25-26 with regard to the features in common with all the concrete blocks.
[0053] Figure 28 shows a top view of a right-hand curve block 230 according to an embodiment and Figure 29 is an isometric illustration of a right-hand curve block according to an embodiment. A mirror image of this right-hand curve block 230 is a left-hand curve block 240 which is shown in Figures 30 and 31. The right-hand curve block 230 and the left-hand curve block 240 are jointly referred to as 'curve blocks' in the following. The curve blocks have a short curved wall 312, a long curved wall 313 and two straight walls 313. The straight walls are non-parallel and preferably the and between the two straight walls is 15° or 22,5° or 30° or 45° to allow making a 90° turn with six, four, three or two curve blocks, respectively. Similar to other concrete blocks of the present disclosure, the curve blocks have protrusions 20 on the top surface 16 and cavities on the bottom surface 18, directly below the protrusions. The curve blocks 230, 240 have a hollow core 50.
[0054] Figure 32 shows a top view of a circular block 250 according to an embodiment and Figure 33 is an isometric illustration of a circular block 250 according to an embodiment. The circular block 250 has a single, continuous, circular wall 252 which forms a periphery of the circular block 250. Preferably, the circular block has the same positions of the protrusions 20 on the top surface 16 and the cavities on the bottom surface as the square concrete block 220 has. Pillars can thus be constructed either with the square concrete blocks 220 or with the circular blocks 250 and they are interchangeable. The circular block 250 has a hollow core 50.
[0055] Figure 34 shows a top view of a long concrete block 260 according to an embodiment. This embodiment is very similar to the interlocking hollow concrete block 10 in Figures 1-4 and Figures 14 and 15. The only difference is the length of the long side wall 14 of the long concrete block 260, which is roughly one third longer than in the embodiment shown in Figures 1-4, 14 and 15. The protrusions 20 have the same spacing as the interlocking hollow concrete block 10 but there are four protrusion on the top surface 16 of the long side wall 14 of the long concrete block 260 instead of three in the interlocking hollow concrete block 10. The long concrete block 260 has a hollow core 50.
[0056] Figure 35 shows a top view of a short concrete block 270 according to an embodiment. This embodiment is very similar to the interlocking hollow concrete block 10 in Figures 1-4 and Figures 14 and 15. The only difference is the length of the long side wall 14 of the short concrete block 270, which is roughly one third of the long side wall 14 of the interlocking hollow concrete block 10 shown in Figures 1-4, 14 and 15. The protrusions 20 have the same spacing as the interlocking hollow concrete block 10 but there is only a single protrusion on the top surface 16 of the long side wall 14 of the short concrete block 270 instead of three in the interlocking hollow concrete block 10. In this embodiment, the long side wall 14 of the short concrete block 270 is actually shorter than the short side wall 12 of the short concrete block 270. The short concrete block 270 has a hollow core 50.
[0057] Figure 36 shows a top view of a partially hollow concrete block 280 according to an embodiment. This embodiment is very similar to the interlocking hollow concrete block 10 in Figures 1-4 and Figures 14 and 15. The only difference is that the partially hollow concrete block 280 has two dividing walls 282 which partially fill a space defined be the long side walls 14 and the short side walls 12. The partially hollow concrete block thus has three hollow sections 285 inside the space defined by its side walls.
[0058] Figure 37 shows a top view of a corner block 290 according to an embodiment. This embodiment is once again very similar to the interlocking hollow concrete block 10 in Figures 1-4 and Figures 14 and 15. The corner block has two long side walls 294 connecting at a 90° angle, two short side walls 292, each connected from one end to one free end of the long side walls 294 at a 90° angle, and two very short side walls 296 connecting at a 90° angle to each other from one end and each of the very short side walls 296 being connected to the short side walls from the other end. Each of the long side walls 294 have three protrusions 20 on the top surface 16 and three cavities on the bottom surface. Each of the short side walls 292 have two protrusions 20 on the top surface 16 and two cavities on the bottom surface. Each of the very short side walls 296 have a protrusion 20 on the top surface 20 and a cavity on the bottom surface. The corner block 290 is mainly used with the interlocking hollow concrete block 10 to strengthen 90° corners in walls instead of building the corners only with the interlocking hollow concrete blocks. The corner block 290 has a hollow core 50.
[0059] It is obvious to the skilled person in the art that, as technology develops, the basic idea of the invention can be implemented in various ways. The invention and its embodiments are therefore not limited to only the examples presented above, rather they may vary within the scope of the claims.
1. An interlocking hollow concrete block (10) having
two long side walls (14) extending in a width direction, and
two short side walls (12) extending in a depth direction perpendicular to the width direction,
where the two short side walls (12) and the two long side walls (14) define a hollow rectangular shape, and
each of the two long side walls (14) and the two short side walls (12) are delimited in a height direction by a top surface (16) in a first plane and a bottom surface (18) in a second plane parallel to the first plane,
where the height direction is parallel to a normal of the first plane, and the height direction is perpendicular to both the width direction and the depth direction, and
each of the two long side walls (14) and each of the two short side walls (12) having protrusions (20) on the top surface (16) and cavities (30) on the bottom surface (18),
where the protrusions (20) are identical in the width direction and the depth direction, and the protrusions (20) are tapered in the height direction, and
each of the cavities (30) is configured to accommodate a protrusion (20) of a similar concrete block (10),
wherein said concrete block (10) is characterized in that each of the two long side walls (14) and the two short side walls (12) forming an obtuse angle with the top surface (16) and each of the two long side walls (14) and the two short side walls (12) forming an acute angle with the bottom surface (18).
2. The interlocking hollow concrete block according to claim 1, where each of the two
long side walls (14) comprises three or more protrusions (20) on the top surface (16)
and three or more cavities (30) on the bottom surface (18), and
each of the two short side walls (12) comprises two or more protrusions (20) on the top surface (16) and two or more cavities (30) on the bottom surface (30).
each of the two short side walls (12) comprises two or more protrusions (20) on the top surface (16) and two or more cavities (30) on the bottom surface (30).
3. The interlocking hollow concrete block according to claim 1 or 2, where the cavities
(30) are identical in the width direction and the depth direction.
4. The interlocking hollow concrete block according to any one of claims 1 to 3, where
each of the protrusions (20) is rotationally symmetrical in a plane parallel to the
first plane.
5. The interlocking hollow concrete block according to any one of claims 1 to 4, where
each of the two long side walls (14) comprises three protrusions (20) on the top surface
(16) and three cavities (30) on the bottom surface (18), and
each of the two short side walls (12) comprises two protrusions (20) on the top surface (16) and two cavities (30) on the bottom surface (30),
wherein a spacing of the protrusions of each of the short side walls (12) is equal to the spacing of the protrusions of each of the long side walls (14).
6. The interlocking hollow concrete block according to any one of claims 1 to 5, where
a distance between any protrusion (20) of the short side walls (12) and the nearest
corner of the concrete block (10) is equal to the distance between the outermost protrusions
(20) of the long side walls and the nearest corner of the concrete block (10).
7. The interlocking hollow concrete block according to any one of claims 1 to 6, where
the spacing of the protrusions of each of the short side walls (12) and each of the
long side walls (14) is twice the distance between any protrusion (20) of the short
side walls (12) and the nearest edge of the concrete block (10) measured along a line
passing through centres of the protrusions (20) of that short side wall (12).
8. The interlocking hollow concrete block according to any one of claims 1 to 7, where
wall thickness of each of the two long side walls (14) and the two short side walls
(12) constantly decreases in height direction, the wall thickness being smallest at
the height of the top surface (16).
9. The interlocking hollow concrete block according to any one of claims 1 to 8, wherein
outer surfaces of each of the two long side walls (14) and the two short side walls
(12) are perpendicular to the top surface (16).
10. A set of concrete blocks comprising the interlocking hollow concrete block (10) of
any one of claims 1 to 9 and a locking block (100), wherein the locking block (100)
has a top surface (116) and a bottom surface (118) which are parallel with each other,
the top surface (116) having a larger surface area than the bottom surface (118),
where the locking block has two long side walls (114) and two short side walls (112),
and each of said side walls forming an acute angle with the top surface (116) and
an obtuse angle with the bottom surface (118), wherein the locking block (100) has
one or more through holes or tubes (110) extending between the top surface (116) and
the bottom surface (118) of the locking block (100).
11. A structure comprising a plurality of the interlocking hollow concrete blocks (10)
according to any one of claims 1 to 9, wherein said structure further comprises a
set of concrete blocks according to claim 10.
12. A structure according to claim 11, wherein said structure further comprises a foundation
(150) and one or more threaded rods (120) fixed to the foundation (150) , where the
one or more threaded rods extend through said through holes or tubes (110) of the
locking block (100).