IP Library Granted Patent US 11,346,559
Granted Patent B2
US 11,346,559 · App. 16/704,222 · Granted May 31, 2022

Bridging lintel with support hangers for an insert and block system for a structure

Inventors: William H. Karau (Southlake, TX); Richard Kenneth Magnuson (Richfield, MN)
Assignee: Keystone Retaining Wall Systems LLC
F24B1/181F24B1/1806F24B1/195
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Quick Facts
Patent No.
US 11,346,559
App. No.
16/704,222
Granted
May 31, 2022
Kind
B2
Abstract

An outdoor structure and structural system including a plurality of structural blocks having opposed top and bottom surfaces, opposed front and rear surfaces and opposed first and second side surfaces, the bottom surfaces of the plurality of structural blocks having a receiving channel extending along the bottom surface from the first side surface towards the second side surface, the receiving channel sized and shaped to receive and retain a hanger. The outdoor structure and structural system also including at least one bridging lintel, the bridging lintel having an upper surface, front and rear sides and first and second sides, the bridging lintel having first and second hangers extending from the upper surface of the bridging lintel, the first hanger extending a distance along the upper surface and a distance outward from the upper surface beyond the first side of the bridging lintel, the second hanger extending a distance along the upper surface and a distance outward from the upper surface beyond the second side of the bridging lintel.

Claims (28)

1. An outdoor structural system comprising:

a plurality of structural blocks having opposed top and bottom surfaces, opposed front and rear surfaces and opposed first and second side surfaces, the bottom surfaces of the plurality of structural blocks having a receiving channel extending along the bottom surface from the first side surface towards the second side surface, the receiving channel sized and shaped to receive and retain a hanger, and

at least one bridging lintel, the bridging lintel having an upper surface, front and rear sides and first and second sides, the bridging lintel having first and second hangers extending from the upper surface of the bridging lintel, the first hanger extending a distance along the upper surface and a distance outward from the upper surface beyond the first side of the bridging lintel, the second hanger extending a distance along the upper surface and a distance outward from the upper surface beyond the second side of the bridging lintel.

2. The outdoor structural system of claim 1 , wherein the at least one bridging lintel forms an uppermost portion of an insert, the insert being a vent, drain, access panel, door, gate, fireplace or appliance.

3. The outdoor structural system of claim 1 , wherein the at least one bridging lintel has a supporting surface extending perpendicular to and upward from the upper surface of the bridging lintel along the rear side from the first side surface to the second side surface of the bridging lintel.

4. The outdoor structural system of claim 1 , wherein the structural blocks are positioned and stacked to form a structure having multiple courses of the structural blocks and wherein the structure includes more than one lower course of structural blocks and at least one upper course of structural blocks, each of the more than one lower courses of structural blocks having a first gap extending a length between first and second structural blocks of each of the more than one lower courses, each first gap of each of the more than one lower course being vertically aligned to form a first insert cavity, the first insert cavity having a height.

5. The outdoor structural system of claim 4 , further comprising a door insert, the door insert including top and bottom frame walls, first and second side frame walls, and a hinged door, the at least one bridging lintel forming the top frame wall of the door insert and wherein the door insert is positioned within the first insert cavity such that the first hanger of the at least one bridging lintel is positioned on the top surface of the first structural block of the uppermost course of the more than one lower courses and the second hanger is positioned on the top surface of the second block of the uppermost course of the more than one lower courses such that the upper surface of the bridging lintel spans the length of the at least first gap of the uppermost course of the more than one lower courses and is substantially flush with the top surfaces of the first and second blocks of the uppermost course of the more than one lower courses.

6. The outdoor structural system of claim 4 , further comprising a fireplace insert, the fireplace insert including top and bottom surfaces, first and second sides, and front and rear sides, the front side having an outward opening, the at least one bridging lintel forming a portion of the top surface along the front side of the fireplace insert extending from the first side to the second side of the fireplace insert, and wherein the fireplace insert is positioned within the first insert cavity such that the first hanger of the at least one bridging lintel is positioned on the top surface of the first structural block of the uppermost course of the more than one lower courses and the second hanger is positioned on the top surface of the second block of the uppermost course of the more than one lower courses such that the upper surface of the at least one bridging lintel spans the length of the gap of the uppermost course of the more than one lower courses and is substantially flush with the top surfaces of the first and second blocks of the uppermost course of the more than one lower courses.

7. The outdoor structural system of claim 4 , further comprising at least first and second bridging lintels and wherein each of the more than one lower courses of structural blocks has a second gap extending a length between third and fourth structural blocks of each of the more than one lower courses, each second gap of each of the more than one lower course being vertically aligned to form a second insert cavity, the second insert cavity having a height.

8. The outdoor structural system of claim 7 , further comprising a fireplace insert, the fireplace insert including top and bottom surfaces, first and second sides, and front and rear sides, the front and rear side each having an outward opening, the first bridging lintel forming a portion of the top surface along the front side of the fireplace insert extending from the first side to the second side of the fireplace insert, the second bridging lintel forming a portion of the top surface along the rear side of the fireplace insert extending from the first side to the second side of the fireplace insert and wherein the fireplace insert is positioned within the first and second insert cavities such that the first hanger of the first bridging lintel is positioned on the top surface of the first structural block of the uppermost course of the more than one lower courses and the second hanger is positioned on the top surface of the second block of the uppermost course of the more than one lower courses such that the upper surface of the bridging lintel spans the length of the first gap of the uppermost course of the more than one lower courses and the first hanger of the second bridging lintel is positioned on the top surface of the third structural block of the uppermost course of the more than one lower courses and the second hanger is positioned on the top surface of the fourth block of the uppermost course of the more than one lower courses such that the upper surface of the second bridging lintel spans the length of the second gap of the uppermost course of the more than one lower courses.

9. The outdoor structural system of claim 7 , wherein the first bridging lintel forms an uppermost portion of a first insert, the first insert being a vent, drain, access panel, door, gate, fireplace or appliance, the insert being positioned in the first insert cavity and wherein the second bridging lintel forms an uppermost portion of a second insert, the second insert being a vent, drain, access panel, door, gate, fireplace or appliance, the insert being positioned in the second insert cavity.

10. An outdoor structure constructed with multiple courses of structural blocks, the outdoor structure comprising:

a plurality of structural blocks having opposed top and bottom surfaces, opposed front and rear surfaces and opposed first and second side surfaces, the bottom surfaces of the plurality of structural blocks having a receiving channel extending along the bottom surface from the first side surface towards the second side surface, the receiving channel sized and shaped to receive and retain a hanger, the plurality of structural blocks including at least one lower course of structural blocks and at least one upper course of structural blocks, the at least one lower course of structural blocks having at least a first gap extending a length between a first and second structural block of the at least one lower course,

at least one bridging lintel, the bridging lintel having an upper surface, front and rear sides and first and second sides, the bridging lintel having first and second hangers extending from the upper surface of the bridging lintel, the first hanger extending a distance along the upper surface and a distance outward from the upper surface beyond the first side of the bridging lintel, the second hanger extending a distance along the upper surface and a distance outward from the upper surface beyond the second side of the bridging lintel,

wherein the at least one bridging lintel is positioned along the at least one lower course of structural blocks such that the first hanger is positioned on the top surface of the first structural block and the second hanger is positioned on the top surface of the second structural block such that the upper surface of the bridging lintel spans the length of the gap and is substantially flush with the top surfaces of the first and second block of the at least one lower course and wherein each of the first and second hangers of the at least one bridging lintel is received and retained within one or more receiving channels in the bottom surfaces of the structural blocks of the at least one upper course.

11. The outdoor structure of claim 10 , wherein the at least one lower course of structural blocks is more than two lower courses of structural blocks and each course of the more than two lower courses of structural blocks has at least a first gap extending a length between a first and second structural block of each of the more than two lower courses of blocks and wherein the at least first gap of one course of the more than two lower courses of structural blocks vertically aligns with the at least first gap of the other courses of the more than two lower courses of structural blocks, the vertically aligned gaps of each of the more than two lower courses of structural blocks creating an insert cavity for an insert, the insert cavity having a height.

12. The outdoor structure of claim 11 , further comprising a door insert, the door insert including top and bottom frame walls, first and second side frame walls, and a hinged door, the at least one bridging lintel forming the top frame wall of the door insert and wherein the first hanger of the at least one bridging lintel is positioned on the top surface of the first structural block of the uppermost course of the more than two lower courses and the second hanger is positioned on the top surface of the second block of the uppermost course of the more than two lower courses such that the upper surface of the bridging lintel spans the length of the of the at least first gap of the uppermost course of the more than two lower courses and is substantially flush with the top surfaces of the first and second blocks of the uppermost course of the more than two lower courses.

13. The outdoor structure of claim 12 , wherein the bridging lintel of the door insert has a supporting surface extending perpendicular to and upward from the upper surface of the bridging lintel along the rear side of the bridging lintel from the first side to the second side of the bridging lintel.

14. The outdoor structure of claim 11 , further comprising a fireplace insert, the fireplace insert including top and bottom surfaces, first and second sides, and front and rear sides, the front side having an outward opening, the at least one bridging lintel forming a portion of the top surface along the front side of the fireplace insert extending from the first side to the second side of the fireplace insert, and wherein the first hanger of the at least one bridging lintel is positioned on the top surface of the first structural block of the uppermost course of the more than two lower courses and the second hanger is positioned on the top surface of the second block of the uppermost course of the more than two lower courses such that the upper surface of the bridging lintel spans the length of the gap of the uppermost course of the more than two lower courses and is substantially flush with the top surfaces of the first and second blocks of the uppermost course of the more than two lower courses.

15. The outdoor structure of claim 14 , wherein the top surface of the fireplace insert has third and fourth hangers extending outwardly from the rear side of the fireplace insert and the third and fourth hangers are positioned on the top surfaces of structural blocks of the uppermost course of the more than two lower courses and wherein the third and fourth hangers are received within rear spaces between adjacently positioned structural blocks of the at least one upper course.

16. The outdoor structure of claim 10 , wherein the at least one bridging lintel forms an uppermost portion of an insert, the insert being a vent, drain or access panel.

17. The outdoor structure of claim 11 , wherein the at least one bridging lintel forms an uppermost portion of an insert, the insert being a door, gate, fireplace or appliance.

18. An outdoor structure constructed with multiple courses of structural blocks, the outdoor structure comprising:

a plurality of structural blocks having opposed top and bottom surfaces, opposed front and rear surfaces and opposed first and second side surfaces, the bottom surfaces of the plurality of structural blocks having a receiving channel extending along the bottom surface from the first side surface towards the second side surface, the receiving channel sized and shaped to receive and retain a hanger, the plurality of structural blocks including more than one lower course of structural blocks and at least one upper course of structural blocks, each of the more than one lower courses of structural blocks having a first gap extending a length between first and second structural blocks of each of the more than one lower courses and each of the more than one lower courses of structural blocks having a second gap extending a length between third and fourth structural blocks of each of the more than one lower courses, each first gap of each of the more than one lower course being vertically aligned to form a first insert cavity, the first insert cavity having a height, each second gap of each of the more than one lower course being vertically aligned to form a second insert cavity, the second insert cavity having a height,

at least first and second bridging lintels, each bridging lintel having an upper surface, front and rear sides and first and second sides, each bridging lintel having first and second hangers extending from the upper surface of the bridging lintel, the first hanger extending a distance along the upper surface and a distance outward from the upper surface beyond the first side of the bridging lintel, the second hanger extending a distance along the upper surface and a distance outward from the upper surface beyond the second side of the bridging lintel,

wherein the first bridging lintel is positioned along the uppermost course of the more than one lower course of structural blocks such that the first hanger is positioned on the top surface of the first structural block of the course of blocks and the second hanger is positioned on the top surface of the second block of the course of blocks such that the upper surface of the bridging lintel spans the length of the first gap and is substantially flush with the top surfaces of the first and second blocks of the uppermost course of the more than one lower course of structural blocks and wherein the second bridging lintel is positioned along the uppermost course of the more than one lower course of structural blocks such that the first hanger is positioned on the top surface of the third structural block of the course of blocks and the second hanger is positioned on the top surface of the fourth block of the course of blocks such that the upper surface of the bridging lintel spans the length of the second gap and is substantially flush with the top surfaces of the third and fourth blocks of the uppermost course of the more than one lower course of structural blocks and wherein each of the first and second hangers of the at least first and second bridging lintels are received and retained within one or more receiving channels in the bottom surfaces of the structural blocks of the upper course.

19. The outdoor structure of claim 18 , further comprising a fireplace insert, the fireplace insert including top and bottom surfaces, first and second sides, and front and rear sides, the front and rear side each having an outward opening, the first bridging lintel forming a portion of the top surface along the front side of the fireplace insert extending from the first side to the second side of the fireplace insert, the second bridging lintel forming a portion of the top surface along the rear side of the fireplace insert extending from the first side to the second side of the fireplace insert and wherein the fireplace insert is positioned within the first and second insert cavities such that the first hanger of the first bridging lintel is positioned on the top surface of the first structural block of the uppermost course of the more than one lower course and the second hanger is positioned on the top surface of the second block of the uppermost course of the more than one lower course such that the upper surface of the bridging lintel spans the length of the first gap of the uppermost course of the more than one lower course and the first hanger of the second bridging lintel is positioned on the top surface of the third structural block of the uppermost course of the more than one lower course and the second hanger is positioned on the top surface of the fourth block of the uppermost course of the more than one lower course such that the upper surface of the second bridging lintel spans the length of the second gap of the uppermost course of the more than one lower course.

20. The outdoor structure of claim 19 , wherein the upper surfaces of the first and second lintels form a trough, each trough having first and second upper supporting surfaces and a recessed surface, the first and second hangers of each bridging lintel being coupled to the recessed surface, the first hanger of each bridging lintel extending upward and outward from the recessed surface beyond the first side surface of each bridging lintel and the second hanger of each bridging lintel extending upward and outward from the recessed surface beyond the second side surface of each bridging lintel and wherein the first and second supporting surfaces of the first bridging lintel are substantially flush with the top surfaces of the first and second blocks of the uppermost lower course of structural blocks and the first and second supporting surfaces of the second bridging lintel are substantially flush with the top surfaces of the third and fourth blocks of the uppermost lower course of structural blocks.

Assignments (4)
PATENT SECURITY AGREEMENT Recorded Feb 10, 2025
From: BEST BLOCK, LLC; CONTECH ENGINEERED SOLUTIONS LLC; CUSTOM BUILDING PRODUCTS, LLC; FORTERRA CONCRETE PRODUCTS, LLC; FORTERRA PIPE & PRECAST, LLC; KEYSTONE RETAINING WALL SYSTEMS LLC; PAVESTONE, LLC; THE QUIKRETE COMPANIES, LLC; UNITED STATES PIPE AND FOUNDRY COMPANY, LLC; USP HOLDINGS, LLC
To: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
Reel/Frame 070170/0919 →
PATENT SECURITY AGREEMENT (ABL) Recorded Mar 23, 2022
From: UNITED STATES PIPE AND FOUNDRY COMPANY, LLC; GRIFFIN PIPE PRODUCTS CO., LLC; CUSTOM FAB, INC.; BIO CLEAN ENVIRONMENTAL SERVICES, INC.; MODULAR WETLAND SYSTEMS, INC.; FORTERRA PIPE & PRECAST, LLC; FORTERRA CONCRETE PRODUCTS, INC.; FORTERRA PRECAST CONCEPTS, LLC; BEST BLOCK, LLC; PAVESTONE, LLC; CONTECH ENGINEERED SOLUTIONS LLC; KEYSTONE RETAINING WALL SYSTEMS LLC
To: WELLS FARGO BANK, NATIONAL ASSOCIATION, AS AGENT
Reel/Frame 059479/0437 →
SECURITY INTEREST Recorded Mar 18, 2022
From: KEYSTONE RETAINING WALL SYSTEMS LLC
To: WELLS FARGO BANK, N.A., AS AGENT
Reel/Frame 059437/0933 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 10, 2020
From: KARAU, WILLIAM H.; MAGNUSON, RICHARD KENNETH
To: KEYSTONE RETAINING WALL SYSTEMS LLC
Reel/Frame 053442/0190 →
Continuity (2)
Provisional Application 62776128 · Dec 6, 2018
Related Publication 20200182473A1 · Jun 11, 2020