Connection surface for a structural unit and method of making same

Abstract

A connection surface disposed on a face of a structural unit comprises a first segment having a three dimensional surface profile including a plurality of positive outer surfaces extending outwardly along a normal direction from a plane and a plurality of negative outer surfaces extending inwardly along the normal direction from the plane, wherein at least two of the plurality of positive outer surfaces are separated from one another along both vertical and horizontal directions and at least two of the plurality of negative outer surfaces are separated from one another along vertical and horizontal directions. A second segment opposes the first segment with respect to an axis, wherein the second segment is a substantial reflection of the first segment across the axis, but reversed along the normal direction.

1 . (canceled) 
     
     
         2 . A connection surface disposed on a face of a structural unit, the face of the structural unit extending generally along a plane, the connection surface comprising:
 a first segment having a three dimensional surface profile including a plurality of positive outer surface features extending outwardly along a normal direction from the plane and a plurality of negative outer surface features extending inwardly along the normal direction from the plane, wherein at least two of the plurality of positive outer surfaces are separated from one another along both directions in an x-y plane and at least two of the plurality of negative outer surfaces are separated from one another along both directions in an x-y plane;   a second segment opposing the first segment with respect to an axis;   wherein the second segment is a substantial reflection of the first segment across the axis, but reversed along the normal direction;   wherein when the connection surface on a face of a first structural unit faces and engages the connection surface on a face of a second structural unit in the same orientation, at least one of the positive outer surfaces of the first segment of the first structural unit nests with at least one of the negative outer surfaces of the second segment of the second structural unit, and at least one of the positive outer surfaces of the second segment of the first structural unit nests with at least one of the negative outer surfaces of the first segment of the second structural unit.   
     
     
         3 . The connection surface of  claim 2 , wherein the two dimensional surfaces of the first and second segments comprise at least one irregular positive or negative surface feature. 
     
     
         4 . A connection surface disposed on a face of a structural unit, the face of the structural unit extending generally along a plane, the connection surface comprising:
 a first pair of segments having a first segment with a three dimensional surface profile including a plurality of positive outer surface features extending outwardly along a normal direction from the plane and a plurality of negative outer surface features extending inwardly along the normal direction from the plane and a second segment opposing the first segment with respect to a first axis, the second segment being a substantial reflection of the first segment across the first axis, but reversed along the normal direction; and   a second pair of segments including a first segment and a second segment, the second pair of segments opposing the first pair with respect to a second axis, the second pair of segments being a substantial reflection of the first pair of segments with respect to the second axis, but reversed along the normal direction;   wherein when the connection surface on a face of a first structural unit faces and engages the connection surface on a face of a second structural unit in the same orientation, at least one of the positive outer surfaces of at least one of the first segments of the first structural unit nests with at least one of the negative outer surfaces of one of the second segments of the second structural unit, and at least one of the positive outer surfaces of at least one of the second segments of the first structural unit nests with at least one of the negative outer surfaces of one of the first segments of the second structural unit.   
     
     
         5 . The connection surface of  claim 4 , wherein the connection surface is configured such that, when the connection surface on a face of a first structural unit faces and mates with the connection surface on a face of a second structural unit, connection profiles are defined along at least two different sections through the mated connection surfaces;
 wherein each of the connection profiles defines a 180-degree rotation about a center point.   
     
     
         6 . The connection surface of  claim 4 , wherein the first and second axes are parallel to one another to provide a book fold between connection surfaces. 
     
     
         7 . The connection surface of  claim 4 , wherein at least two of the plurality of positive outer surfaces of at least one of the segments are separated from one another along both directions in an x-y plane and at least two of the plurality of negative outer surfaces are separated from one another along both directions in an x-y plane. 
     
     
         8 . The connection surface of  claim 4 , wherein the first and second axes are perpendicular to one another;
 wherein the first axis provides a y-axis and the second axis provides an x-axis in an x-y plane;   wherein the first and second segments of the first pair of segments provide first and second quadrants, respectively, and wherein the first and second segments of the second pair of segments provide third and fourth quadrants, respectively;   wherein the first and third quadrants are substantial reflections of one another with respect to the x-axis, but reversed along the normal direction; and   wherein the second and fourth quadrants are substantial reflections of one another with respect to the x-axis, but reversed along the normal direction.   
     
     
         9 . The connection surface of  claim 8 , wherein the connection surface is configured such that, when the connection surface on a face of a first structural unit faces and engages the connection surface on a face of a second structural unit, the connection surfaces nest with one another when the x-y planes of both connection surfaces are in a vertical orientation or reversed vertical orientation. 
     
     
         10 . The connection surface of  claim 8 , wherein the connection surface is configured such that, when the connection surface on a face of a first structural unit faces and engages the connection surface on a face of a second structural unit, the connection surfaces nest with one another when the x-y planes of both connection surfaces are in a horizontal orientation or reversed horizontal orientation. 
     
     
         11 . The connection surface of  claim 4 , further comprising:
 a third pair of segments including first and second segments opposing one another with respect to the first axis and separated from one another by the first and second pairs of segments, the first segment of the third pair being a substantial reflection of the second segment of the third pair with respect to the first axis, but reversed along the normal direction; and   a fourth pair of segments including first and second segments opposing one another with respect to the first axis and separated from one another by the first and second pairs of segments, the first segment of the fourth pair being a substantial reflection of the second segment of the fourth pair with respect to the first axis, but reversed along the normal direction;   wherein the first segment of the third pair and the first segment of the fourth pair oppose one another with respect to the second axis, the first segment of the third pair being a substantial reflection of the first segment of the third pair with respect to the second axis, but reversed along the normal direction; and   wherein the second segment of the third pair and the second segment of the fourth pair oppose one another with respect to the second axis, the second segment of the third pair being a substantial reflection of the second segment of the third pair with respect to the second axis, but reversed along the normal direction.   
     
     
         12 . The connection surface of  claim 11 , wherein the first and second segments of the third and fourth pairs of segments are substantially identical to the first and second segments of the first and second pairs of segments. 
     
     
         13 . The connection surface of  claim 4 , wherein the first and second segments of each pair of segments are adjacent to one another. 
     
     
         14 . The connection surface of  claim 13 , wherein edges of the first and second segments of each pair of segments define a seam; and
 wherein the first and second segments of at least one pair of segments have portions removed on or adjacent to the seam.   
     
     
         15 . The connection surface of  claim 4 , wherein at least one of the plurality of positive or negative surface features in the first segment of each pair of segments has a portion removed such that the at least one positive surface feature extends outwardly in the normal direction to a lesser amount than a complementary negative surface feature in the second segment of each pair of segments extends inwardly;
 wherein when the connection surface on a face of a first structural unit faces and engages the connection surface on a face of a second structural unit, a gap is defined between the at least one positive surface feature and the at least one negative surface feature.   
     
     
         16 . A structural unit comprising:
 top and bottom faces;   first and second side faces;   first and second end faces; and   the connection surface of  claim 4  disposed on at least one of the faces.   
     
     
         17 . The structural unit of  claim 16 , wherein the structural unit comprises a structural wall unit. 
     
     
         18 . The structural unit of  claim 16 , wherein the structural unit comprises a paver. 
     
     
         19 . The structural unit of  claim 16 , wherein the structural unit comprises a concrete masonry unit, retaining wall block, patio stone, edger, curb, cap, fence panel, precast wall panel, wall covering, interior wall panel, and or revetment mat. 
     
     
         20 . A method for providing a connection surface for a structural unit, the method comprising:
 providing a primary surface having a three dimensional surface profile along a plane including a plurality of positive outer surfaces extending outwardly along a normal direction from the plane and a plurality of negative outer surfaces extending inwardly along the normal direction from the plane, wherein at least two of the plurality of positive outer surfaces are separated from one another along both directions in an x-y plane and at least two of the plurality of negative outer surfaces are separated from one another along both directions in an x-y plane;   providing a secondary surface, where the secondary surface is a reflection of the primary surface and reversed along a normal direction;   assembling the primary and secondary surfaces according to a surface reflection pattern along the plane to provide a surface texture; and   forming the provided surface texture on a surface of the structural unit.   
     
     
         21 . The method of  claim 20 , wherein said providing a primary surface comprises generating the primary surface based on one or more parameters.