IP Library Granted Patent US 11,034,062
Granted Patent B2
US 11,034,062 · App. 16/812,851 · Granted Jun 15, 2021

Manufactured retaining wall block with improved false joint

Inventor: William H. Karau (Southlake, TX)
Assignee: PAVESTONE, LLC
B29C41/36B28B7/00B28B7/007B28B7/0097B28B7/183B28B7/28B28B17/0027E02D29/02E02D29/025E02D29/0266E04B2/32E04C1/00E04C1/395E04B2002/0208E04B2002/0219E04B2002/0269
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Quick Facts
Patent No.
US 11,034,062
App. No.
16/812,851
Granted
Jun 15, 2021
Kind
B2
Abstract

A retaining wall block having a false joint and a system of retaining wall blocks. The retaining wall block includes a body having a first textured surface and a second textured surface and a false joint dividing the first and second textured surface. The false joint can have a depth divided by the width greater than two inches. The false joint can have an interior angle of less than ten degrees. The system includes a plurality of retaining wall blocks and a first course of retaining wall blocks engaged with a second course of retaining wall blocks below. Each block in the system comprising a front face having a first textured surface and a second textured surface and a false joint dividing the first and second textured surface. The false joint can extend a predetermined depth of a third surface.

Claims (29)

1. A method of manufacturing a retaining wall block comprising:

forming a body having a first surface and a second surface; and

forming a false joint dividing the first and second surface and extending a predetermined depth of the body, wherein the false joint includes a tapered interior portion having a first taper angle, a tapered exterior portion having a second taper angle and a transition region where the second taper angle reduces to the first taper angle;

wherein the false joint has an interior angle of less than 20 degrees that extends for a predetermined distance over a length in the false joint.

2. The method of claim 1 wherein a depth of the tapered interior portion of the false joint divided by a width of the tapered interior portion of the false joint is greater than 2.

3. The method of claim 1 wherein a depth of the tapered interior portion of the false joint divided by a width of the tapered interior portion of the false joint is less than 3.

4. The method of claim 1 wherein the false joint has an exterior angle of greater than 40 degrees that extends for a predetermined distance over a length in the false joint.

5. The method of claim 1 wherein the first and second surface are textured.

6. The method of claim 1 wherein the false joint extends at least a third of a depth of the body.

7. The method of claim 1 further comprising:

forming a base behind the first surface and the second surface of the body and having at least one ridge to produce at least one engagement cavity.

8. The method of claim 7 wherein the body and base define an H-shaped structure.

9. A method for forming a retaining wall, the method comprising:

forming a first course of a plurality of retaining wall blocks, each block comprising:

a front face having a first surface and a second surface; and

a false joint dividing the first and second surface and extending a predetermined depth of a third surface, the false joint having an interior angle and an exterior angle that is greater than the interior angle; and

forming a second course of retaining wall blocks above the first course;

wherein the false joint has an exterior angle of greater than 40 degrees that extends for a predetermined distance over a length in the false joint.

10. The method of claim 9 wherein a depth of the interior angle of the false joint divided by a width of the interior angle of the false joint is greater than 2.

11. The method of claim 9 wherein a depth of the interior angle of the false joint divided by a width of the interior angle of the false joint is less than 3.

12. The method of claim 9 wherein the false joint has an interior angle of less than 20 degrees that extends for a predetermined distance over a length in the false joint.

13. The method of claim 9 wherein the first and second surface are textured.

14. The method of claim 9 wherein the false joint extends a third or less of a depth of the body.

15. The method of claim 9 further comprising the third surface having at least one engagement protrusion, wherein the at least one engagement protrusion of a first retaining wall block are configured to engage at least one engagement cavity of an adjacent retaining wall block.

16. The method of claim 15 wherein the at least one engagement protrusion and the at least one engagement cavity of a retaining wall block in the first course and a retaining wall block in the second course are of different dimensions to allow the retaining wall block in the first course and the retaining wall block in the second course to interlock.

17. The method of claim 15 , wherein the at least one engagement protrusion of a retaining wall block in the first course of retaining wall blocks is configured to engage with the at least one engagement cavity of a retaining wall block in the second course of retaining wall blocks below.

18. The method of claim 15 , wherein the at least one engagement cavity of a retaining wall block in the second course of retaining wall blocks is configured to engage with the at least one engagement protrusion of a retaining wall block in the first course of retaining wall blocks below.

19. The method of claim 1 wherein the false joint has an exterior angle of greater than 40 degrees that extends for a predetermined distance over a length in the false joint and wherein the false joint extends at least a third of a depth of the body.

20. The method of claim 1 wherein the false joint extends at least a third of a depth of the body and wherein a depth of the tapered interior portion of the false joint divided by a width of the tapered interior portion of the false joint is greater than 2.

Assignments (7)
ENTITY CONVERSION - DE TO GA Recorded Jul 15, 2025
From: PAVESTONE, LLC
To: PAVESTONE, LLC
Reel/Frame 071931/0588 →
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 059479/0336 →
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: PAVESTONE, LLC
To: WELLS FARGO BANK, N.A., AS AGENT
Reel/Frame 059314/0234 →
CHANGE OF ADDRESS OF ASSIGNEE Recorded Sep 16, 2020
From: PAVESTONE, LLC
To: PAVESTONE, LLC
Reel/Frame 053790/0860 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 9, 2020
From: KARAU, WILLIAM H.
To: PAVESTONE, LLC
Reel/Frame 052054/0508 →
Continuity (8)
Continuation 15978891 · May 14, 2018
Continuation In Part 15688784 · Aug 28, 2017
Continuation 15074830 · Mar 18, 2016
Continuation 14311194 · Jun 20, 2014
Continuation In Part 15080276 · Mar 24, 2016
Continuation In Part 29543176 · Oct 21, 2015
Provisional Application 61838205 · Jun 21, 2013
Related Publication 20200230849A1 · Jul 23, 2020