Building block

Abstract

A block has a finished surface that provides an attractive appearance. The block is relatively large in size, allowing the quick construction of a wall, such as a retaining wall, using the block. The block includes one or more lift devices embedded in the block that allow the block to be lifted using a suitable lifting apparatus, such as a crane, forklift, backhoe, etc. The block includes multiple retaining knobs that protrude from the lower surface of the block and help to align a block with previously-laid blocks underneath. The block includes multiple voids that extend from the top surface to the bottom surface of the block, and that align with each other when the blocks are stacked into a wall, thereby allowing fill material to be placed in the voids to strengthen the wall. The block is constructed using a block forming apparatus that includes one or more form panels that each have multiple form liners to provide a textured surface of the block. Each form panel may be pivoted away from a bottom surface of the block forming apparatus for easy removal of the block and for easy changing of the panels to fabricate blocks with different characteristics using the same block forming apparatus. The preferred embodiments also include methods for doing business, including the selling, leasing, and purchasing of the block forming apparatus for on-site fabrication of blocks.

1 . A block comprising: 
 a front surface;    first and second side surfaces coupled to the front surface;    a top surface coupled to the front surface and to the first and second side surfaces;    a bottom surface coupled to the front surface and to the first and second side surfaces, the bottom surface including at least one retaining knob that aligns the bottom surface of the block to the top surface of a previously-placed block;    a plurality of voids extending from the top surface to the bottom surface; and    a sloped back surface coupled to the first and second side surfaces, to the top surface, and to the bottom surface, the back surface sloping from the top surface to the bottom surface.    
     
     
         2 . The block of  claim 1  further comprising: 
 at least one lifting device embedded in the block and partially exposed at the top surface of the block that allows lifting of the block.  
 
     
     
         3 . The block of  claim 1  wherein the block comprises a mixture of sand, gravel, water, and cement in a mix rated at approximately 3000 pounds per square inch (209 kilograms per square centimeter).  
     
     
         4 . The block of  claim 1  wherein the at least one retaining knob extends downward and is located behind and adjacent to the top surface of the previously-placed block when the block is stacked atop the previously-placed block.  
     
     
         5 . The block of  claim 1  wherein the slope of the back surface is in the range of 5 to 25 degrees.  
     
     
         6 . The block of  claim 5  wherein the slope of the back surface is approximately 15 degrees.  
     
     
         7 . A block comprising: 
 a front surface;    first and second side surfaces coupled to the front surface;    a top surface coupled to the front surface and to the first and second side surfaces;    a bottom surface coupled to the front surface and to the first and second side surfaces, the bottom surface including a plurality of retaining knobs that align the bottom surface of the block to the top surface of a previously-placed block, the retaining knobs extending downward from the bottom surface and located behind and adjacent to the top surface of the previously-placed block when the block is stacked atop the previously-placed block;    a plurality of voids extending from the top surface to the bottom surface;    a sloped back surface coupled to the first and second side surfaces, to the top surface, and to the bottom surface, the back surface sloping from the top surface to the bottom surface at an angle of approximately 15 degrees;    at least one lifting device embedded in the block and partially exposed at the top surface of the block that allows lifting of the block;    wherein the block comprises a mixture of sand, gravel, water and cement in a mix rated at approximately 3000 pounds per square inch (209 kilograms per square centimeter).    
     
     
         8 . A block forming apparatus for forming a block, the block forming apparatus comprising: 
 a bottom portion having a length and a width;    front and back portions along the length of the bottom portion and coupled to the bottom portion;    two side portions along the width of the bottom portion and coupled to the bottom portion;    the bottom portion, front and back portions, and side portions forming sides of a substantially open box structure;    at least one of the front and back portions and the side portions including a plurality of form pockets defined by a metal frame, each form pocket receiving a form liner that defines a textured surface of the block.    
     
     
         9 . The block forming apparatus of  claim 8  wherein the front portion, back portion, and two side portions are pivotally coupled to the bottom portion.  
     
     
         10 . The block forming apparatus of  claim 8  further comprising a plurality of void forms attached to the bottom portion that create a plurality of voids in the block.  
     
     
         11 . A block forming apparatus for forming a block, the block forming apparatus comprising: 
 a bottom portion having a length and a width;    front and back portions along the length of the bottom portion and coupled to the bottom portion;    two side portions along the width of the bottom portion and coupled to the bottom portion;    the bottom portion, front and back portions, and side portions forming sides of a substantially open box structure;    at least one of the front and back portions and the side portions including a plurality of form liners that defines a textured surface of the block.    
     
     
         12 . The block forming apparatus of  claim 11  wherein the front portion, back portion, and two side portions are pivotally coupled to the bottom portion.  
     
     
         13 . The block forming apparatus of  claim 11  further comprising a plurality of void forms attached to the bottom portion that create a plurality of voids in the block.  
     
     
         14 . A method for manufacturing a block comprising the steps of: 
 (A) preparing a form comprising a bottom portion having a length and a width, front and back portions along the length of the bottom portion and coupled to the bottom portion, and two side portions along the width of the bottom portion and coupled to the bottom portion, the bottom portion, front and back portions, and side portions forming sides of a substantially open box structure, at least one of the front and back portions and the side portions including a plurality of form pockets defined by a metal frame, each form pocket receiving a form liner that defines a textured surface of the block;    (B) pouring a layer of block mix within the open box structure of the form;    (C) vibrating the block mix;    (D) if the form is not full, adding rebar and repeating steps (B) and (C);    (E) if the form is full, leveling the block mix to a desired height;    (F) allowing the block to cure;    (G) removing the front and back portions and the two side portions from the cured block; and    (H) removing the cured block from the bottom portion.    
     
     
         15 . The method of  claim 14  wherein the form liner is a polyurethane form liner.  
     
     
         16 . A method for manufacturing a block comprising the steps of: 
 (A) preparing a form comprising a bottom portion having a length and a width, front and back portions along the length of the bottom portion and coupled to the bottom portion, and two side portions along the width of the bottom portion and coupled to the bottom portion, the bottom portion, front and back portions, and side portions forming sides of a substantially open box structure, at least one of the front and back portions and the side portions including a plurality of form liners that defines a textured surface of the block;    (B) pouring a layer of block mix within the open box structure of the form;    (C) vibrating the block mix;    (D) if the form is not full, adding rebar and repeating steps (B) and (C);    (E) if the form is full, leveling the block mix to a desired height;    (F) allowing the block to cure;    (G) removing the front and back portions and the two side portions from the cured block; and    (H) removing the cured block from the bottom portion.    
     
     
         17 . The method of  claim 16  wherein the form liner is a polyurethane form liner.  
     
     
         18 . A method for building a block wall comprising the steps of: 
 (A) laying a base course of blocks, each block in the base course comprising: 
 a front surface;  
 first and second side surfaces coupled to the front surface;  
 a top surface coupled to the front surface and to the first and second side surfaces;  
 a bottom surface coupled to the front surface and to the first and second side surfaces;  
 a plurality of voids extending from the top surface to the bottom surface; and  
 a sloped back surface coupled to the first and second side surfaces, to the top surface, and to the bottom surface, the back surface sloping from the top surface to the bottom surface;  
   (B) laying subsequent courses of blocks, each block in each subsequent course comprising: 
 a front surface;  
 first and second side surfaces coupled to the front surface;  
 a top surface coupled to the front surface and to the first and second side surfaces;  
 a bottom surface coupled to the front surface and to the first and second side surfaces, the bottom surface including at least one retaining knob that aligns the bottom surface of the block to the top surface of a previously-placed block;  
 a plurality of voids extending from the top surface to the bottom surface; and  
 a sloped back surface coupled to the first and second side surfaces, to the top surface, and to the bottom surface, the back surface sloping from the top surface to the bottom surface;  
   wherein each block is placed in each subsequent course by positioning the at least one retaining knob adjacent to and behind the top surface of the previously-placed block.    
     
     
         19 . The method of  claim 16  further comprising the step of filling the plurality of voids with a filler material.  
     
     
         20 . A method for doing business comprising the steps of: 
 manufacturing the block forming apparatus of  claim 8;  and    selling or leasing the block forming apparatus for on-site block construction.    
     
     
         21 . A method for doing business comprising the steps of: 
 manufacturing the block forming apparatus of  claim 11;  and    selling or leasing the block forming apparatus for on-site block construction.    
     
     
         22 . A method for doing business comprising the steps of: 
 purchasing the block forming apparatus of  claim 8;  and    selling or leasing the block forming apparatus for on-site block construction.    
     
     
         23 . A method for doing business comprising the steps of: 
 purchasing the block forming apparatus of  claim 11;  and    selling or leasing the block forming apparatus for on-site block construction.    
     
     
         24 . A method for doing business comprising the steps of: 
 purchasing the block forming apparatus of  claim 8;     transporting the block forming apparatus to a job site; and    using the block forming apparatus to fabricate a plurality of blocks on the job site.    
     
     
         25 . A method for doing business comprising the steps of: 
 purchasing the block forming apparatus of  claim 11;     transporting the block forming apparatus to a job site; and    using the block forming apparatus to fabricate a plurality of blocks on the job site.