DESC:FIELD OF THE INVENTION
The present invention relates to a modular block and a structure formed therewith.

BACKGROUND OF THE INVENTION
Reinforced soil walls are commonly used for infrastructural and architectural applications. Such walls are subjected to very high pressures exerted and therefore require high tensile reinforcement members such as geogrids and a connected wall fascia such as modular blocks to secure the structure.

With the advancement of technology, the process of developing a structure including a wall structure has seen a paradigm shift. The wall structure primarily includes placing of concrete block over each other or sideways to raise the structure. These blocks are typically connected with geogrids, which are the primary soil reinforcing elements, where the geogrids are placed horizontally between two block layers. The concrete block may have an interconnection system for securing the blocks while creating a structure. However, the design of the concrete blocks currently available have multiple shortcomings such as leaving a larger gap between blocks when interconnected with each other. Modular blocks currently used weigh ~40kg each, this poses a safety hazard especially in handling the blocks, as they are typically handled manually. Yet another shortcoming of the currently available large sized modular blocks is that it is only feasible to produce one block at a time in most machines, resulting in high manufacturing cost and time.

Conventionally used modular blocks offer insufficient connection strength with geogrids as they lack developed inter-connecting parts, one such example is disclosed in US Patent 8684633 B2 which fails to disclose a securing mechanism to inter-connect the modular blocks. This can be dangerous especially when the reinforced structures are subjected to high pressures.

Therefore, the interconnection system of blocks requires modification, in order to provide a much more secured connection between the blocks and geogrids for creating a robust structure.

Therefore, the object of the present invention is to solve one or more of aforementioned issues.

SUMMARY OF THE INVENTION
A modular block is described. The modular block comprising a base plan, and a protruding part projecting from a bottom surface of the base plan for interconnecting modular blocks.

A modular block system is described. The modular block system formed with plurality of modular blocks, each having a protruding part and a base plan, wherein the surface area of the protruding part is less than the area of the base plan, such that the lower surface area offered by the protruding part concentrates the force onto a lesser area that results in increased pressure and thereby a high connection value is offered by the modular block system.

A modular block structure is described. The modular block structure formed by placing a plurality of modular blocks sideways such that the extending part of any two modular blocks forms a cavity, which is optionally filled with industrially acceptable fillers; and at least one other modular block placed over the plurality of modular blocks such that the protruding part of the modular block is locked within the cavity.

BRIEF DESCRIPTION OF DRAWINGS
Reference will be made to embodiments of the invention, example of which may be illustrated in the accompanying figure(s). These figure(s) are intended to be illustrative, not limiting. Although the invention is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 shows a bottom view of a modular block according to an embodiment of the present invention;
Figure 2 shows a modular block according to an embodiment of the present invention;
Figure 3 shows a top surface of a base plan of a modular block according to an embodiment of the present invention;
Figure 4 shows a side view of a modular block according to an embodiment of the present invention;
Figure 5 shows a top surface view of a modular block according to an embodiment of the present invention;
Figure 6 shows a bottom surface view of a modular block according to an embodiment of the present invention;
Figures 7, and 8 shows a protruding part of a modular block according to an embodiment of the present invention;
Figure 9 shows a modular block structure according to an embodiment of the present invention;
Figure 10 shows a modular block according to an embodiment of the present invention;
Figure 11 shows modular blocks for testing according to an embodiment of the present invention;
Figure 12 shows a graph of connection strength of modular blocks according to an embodiment of the present invention; and
Figure 13 shows an overall view of the test system according to an embodiment of the present system.

DETAILED DESCRIPTION OF THE INVENTION
A modular block is described. The modular block comprising a base plan, and a protruding part projecting from a bottom surface of the base plan for interconnecting modular blocks.

According to the present invention, the base plan of the modular block comprises of at least a front portion, an extending part; and a rear portion.

According to the present invention, the front portion comprises a front surface, a first inclined part affixed to the front surface, a second inclined part affixed to the first inclined part, a third inclined part affixed to the second inclined part, a fourth inclined part affixed to the third inclined part, and a hind surface affixed with the fourth inclined part.

According to the present invention, the extending part has a concave curve on opposite sides and interconnects the front portion with the rear portion.

According to the present invention, the protruding part extends from the base plan at a height in the range of 13mm to 19mm, and has three sloping sides leaving one side straight. The height of the protruding part from the base plan is preferably 16mm.

According to the present invention, the protruding part extends from the base plan and is located over the front portion and the extending part, wherein the sloping sides of the protruding part are structurally matched with the curved sides of the extending part.

According to the present invention, the protruding part has a top face such that the area of the top face to the area of the base plan ratio is in the range of 10% to 13%, preferably 10.5%.

According to the present invention, the rear portion comprises a first rear surface, a curvature part affixed to the first rear surface, a first inclined part affixed to the curvature part, and a second rear surface affixed to the first inclined part.

A modular block system is described. The modular block system formed with plurality of modular blocks, each having a protruding part and a base plan, wherein the surface area of the protruding part is less than the area of the base plan, such that the lower surface area offered by the protruding part concentrates the force onto a lesser area that results in increased pressure and thereby a high connection value is offered by the modular block system.

A modular block structure is described. The modular block structure formed by placing a plurality of modular blocks sideways such that the extending part of any two modular blocks forms a cavity, which is optionally filled with industrially acceptable fillers; and at least one other modular block placed over the plurality of modular blocks such that the protruding part of the modular block is locked within the cavity.
An example of protruding part is described. The protruding part provides a secure interconnection between the modular blocks. The protruding part has a tapered or slope surface extending outward from the base plan. The protruding part has three (3) sides which are slope or tapered and one of the side is straight.
An example of structure formed with a modular block is described. The structure comprises of at least two blocks placed sideways or over each other. In an embodiment comprising multiple blocks, the blocks are first arranged sideways next to each other forming a first row and thereafter the blocks are placed over one other, with the protruding part being placed in the concave structure formed by sideways placement of the blocks. The placement of the protruding part in the concave curve provides a secure interconnection between the blocks placed in the first row and the second row. The protruding part restricts the movement of the block, in addition, the protruding part helps in securing geogrid adapted between the modular blocks.
The subject matter is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purpose of explanation, numerous specific details are set forth in order to provide a thorough understanding of the claimed subject matter. It may be evident however, that such matter can be practiced with these specific details. In other instances, well-known structures as shown in diagram form in order to facilitate describing the invention.
Referring Figure 1, a bottom view of a modular block (100) is shown according to an embodiment of the present invention. The modular block (100) comprises a base plan (110), and a protruding part (120) projecting from a bottom surface (114) of the base plan (110) for interconnecting modular blocks.
Referring Figure 2, a modular block (100) is shown according to an embodiment of the present invention. The modular block (100) comprises a base plan (110), and a protruding part (120). As shown in Figure 2, the base plan (110) of the modular block comprises a front portion (111), an extending part (112), and a rear portion (113).
Referring Figure 3, a top surface (115) of a base plan (110) of a modular block (100) is shown according to an embodiment of the present invention.
Referring Figure 4, a side view of a modular block (100) is shown according to an embodiment of the present invention.
Referring Figure 5, a top surface of a modular block (100) is shown according to an embodiment of the present invention.
Referring Figure 6, a bottom surface of a modular block (100) is shown according to an embodiment of the present invention.
Referring Figures 7, and 8, a protruding part (120) of a modular block (100) is shown according to an embodiment of the present invention. The protruding part (120) comprises three slope sides (121, 122, 123), and one straight side (124).
As shown in Figures 7, and 8, the protruding part (120) has a top face (125). The height of top face (125) from the bottom surface is 16mm.
Referring Figure 9, a modular block structure (200) is shown according to an embodiment of the present invention. The modular block structure (200) comprises first modular block (210), and a second modular block (220) arranged sideways. The first modular block (210), and the second modular block (220) form a cavity (230).
Referring Figure 10, a bottom view of a modular block (100) is shown according to an embodiment of the present invention. As shown in Figure 10, the modular block (100) comprises a base plan (110), and a protruding part (120) projecting from a bottom surface (114) of the base plan (110) for interconnecting modular blocks.
The base plan (110) comprises a front portion (111), an extending part (112), and a rear portion (113). The extending part (112) connects the front portion (111) with the rear portion (113). The front portion (111), the extending part (112), and the rear portion (113) form a concave curve shape structure between the front portion (111) and the rear portion (113).
As shown in Figure 10, the front portion (111) comprises a front surface (11101), a first inclined part (11102, 11103) affixed to the front surface (11101), a second inclined part (11104, 11105) affixed to the first inclined part (11102, 11103), a third inclined part (11106, 11107) affixed to the second inclined part (11104, 11105), a fourth inclined part (11108, 11109) affixed to the third inclined part (11106, 11107), and a hind surface (11110, 11111) affixed with the fourth inclined part (11108, 11109).
As shown in Figure 10, the hind surface (11110, 11111) of the front portion (111) is connected to the extending part (112). The extending part (112) comprise a concave curvature (1121, 1122).

As shown in Figure 10, the extending part (112) is fastened to the rear portion (113). The rear portion (113) comprises a first rear surface (1131, 1132), a curvature part (1133, 1134) affixed to the first rear surface (1131, 1132), a first inclined part (1135, 1136) affixed to the curvature part (1133, 1134), and a second rear surface (1137) affixed to the first inclined part (1135, 1136).

As shown in Figure 10, the protruding part (120) is secured to the base plan (110). The protruding part (120) comprises a bottom surface (1201), and a top face (125) extending from the bottom surface (1201). The bottom surface (1201) comprises a front bottom area (1203) on the front portion (111), anda extend bottom area (1204) on the extending part (112).

As shown in Figure 10, the top face (125) extending from the bottom surface (1201) of the protruding part (120) comprises a top face length (1205), a top face width (1207), and a top face height (1206) from the bottom surface (1201).

As shown in Figure 10, the side formed between the front bottom area (1203) and top face (125) is straight.
The dimensions of the modular block is described as follows:
S. No. Feature Dimension
1 Base Plan (110)
1.1 Front Portion (111)
1.1.1 a front surface (11101) 252 mm
1.1.2.A a first inclined part (11102) affixed to the front surface (11101) 102 mm
1.1.2.B a first inclined part (11103) affixed to the front surface (11101) 80 mm
1.1.3 a second inclined part (11104, 11105) affixed to the first inclined part (11102, 11103) 13 mm
1.1.4 a third inclined part (11106, 11107) affixed to the second inclined part (11104, 11105) 10 mm
1.1.5 a fourth inclined part (11108, 11109) affixed to the third inclined part (11106, 11107) 23 mm
1.1.6 a hind surface (11110, 11111) affixed with the fourth inclined part (11108, 11109) 106 mm
1.1.7 a length (11113) of front portion (111) 430 mm
1.1.8 a length (11115) 102 mm
1.1.9 a length (11114) 76 mm
1.1.10 a curvature (11117) 25.77 degree
1.1.11 a curvature (11116) 33.63 degree
1.1.12 a distance (11118) between the front surface (11101) and the second rear surface (1137) 230 mm

1.1.13 a distance (11112) between the front surface (11101) and the a hind surface (11110, 11111) 85 mm
1.1.14 a distance (11119) between the extend bottom area (1204) on the extending part (112) and the second rear surface (1137) 75 mm
1.2 Extending part (112)
1.2.1 a concave curvature (1121, 1122) R43
1.3 Rear Portion (113)
1.3.1 a first rear surface (1131, 1132) 40 mm
1.3.2 a curvature part (1133, 1134) affixed to the first rear surface (1131, 1132) R15
1.3.3 a first inclined part (1135, 1136) affixed to the curvature (1133, 1134) 37 mm
1.3.4 a second rear surface (1137) affixed to the first inclined part (1135, 1136) 227 mm
1.3.5. a distance (1138) between the hind surface (11111) and the first rear surface (1132) 91 mm
2 Protruding part (120)
2.1 a bottom surface (1201)
2.1.1 a front bottom area (1203) on the front portion (111) 139 mm
2.1.2 a extend bottom area (1204) on the extending part (112). 134 mm
2.2 a top face (125) extending from the bottom surface (1201)
2.2.1 a top face length (1205) of the top face (125) on the front portion (111) 103 mm
2.2.2 a top face width (1207) of the top face (125) 59 mm
2.2.3. a top face height (1206) from the bottom surface (1201). 16 mm
2.3 a distance (1208) between the front bottom area (1203) on the front portion (111) and the extend bottom area (1204) on the extending part (112) 75 mm
2.4 a distance (1209) between the front surface (11101) and the front bottom area (1203) on the front portion (111) 80 mm

The detailed analysis of conducting the test to determine the strength of the modular block is described. For instance, an analysis of determining these kinds of model blocks is described.

The protruding part to base plan area ratio is around 10.5%. As a result, the connection strength, which is dependent on the contact pressure between the protruding part and the geogrid reinforcement, is improved. Based on test results, the connection strength is as high as 120% of the long term design strength of the geogrid reinforcement at peak loads.

EXPERIMENTAL DATA
The connection strength of modular block (Model 2) made using the present invention was tested and compared to strength values of modular block (Model 1). The modular blocks having specific dimensions as seen in Figure 11 were used for the test along with geogrids.

A combined graph of connection strength of the modular block (Model 2) of present invention and the Model 1 is shown in Figure 12, wherein the connection strength of the modular block (Model 2) of present invention is higher by 5-8% even though the size of the modular block (Model 2) of the present invention is less than the size of the modular block (Model 1).

The significant dimensions of the block used were 430 mm length on the front portion and 227mm on the rear portion and a length of 230mm into soil. The height of the blocks is 203mm. Each block having a 16mm high protruding part and plan dimensions as 59x103mm. These protruding parts help in interlocking of different layers of blocks and allows for inward batter of 15mm for every block height.

All laboratory tests were performed in a large tank of 2m length, 1m wide and 1m height. The test system consists of facility for applying uniform vertical load over the width of geogrid sample to stimulate different heights of the wall and facility to apply pullout loads through hydraulic actuator that can be run at speeds of 1mm to 20 mm per minute. The overall view of the test system is shown in Figure 13. All tests were performed as per the recommendations of ASTM D6638-18. Vertical and horizontal loads were applied against self-reacting rigid steel frames. Two full blocks were fixed within the width of the tank. The width of the geogrid layer used in each test was 750mm. The space within the blocks was filled with stone chips passing 20mm sieve. The blocks were restrained laterally to prevent their movement when the pullout load is applied on the geogrid.

The uniform vertical load was applied through a dual hydraulic jack system connected to two separate electronic load cells to measure the applied vertical load. The pullout load on the geogrid was applied through a servo-controlled hydraulic actuator that can be run at speeds of 1 to 20 mm per minute. The pullout load was measured through a 150 kN capacity electronic load cell. The pullout displacements were measured at the facing block itself using an electronic LVDT of 100mm capacity.

The vertical line load applied on the blocks was converted to equivalent height assuming that the blocks and the aggregate filled in the openings will have a unit weight of 24 kN/m3. The relation between the line load (P) and the equivalent wall height (H) is obtained as:
P = 24 ? H ?0.230 ? H (m) ? 0.181 ? P (kN/m)
The tests were performed with different vertical load levels and different geogrids.

CONCLUSION
The connection capacities were analyzed by liner regression technique to develop equations to estimate the connection capacities at different normal loads. An examination of the data shows that the connection capacity rapidly increases initially with increase in the normal load.

Protruding part area to base plan area ratio was 14.1% higher in the modular blocks (Model 2) of the present invention even though the total base area of the block was less than that of the other modular blocks.
The connection strength of modular blocks (Model 2) of the present invention was tested to be 5-8% higher than other modular blocks even though the size of the modular blocks (Model 2) of the present invention is less than the size of the other modular blocks. A resulting improvement in connection pressure was seen.

Apart from technical merit, there is substantial cost savings in concrete materials, improvement in health and safety norms as the blocks are handled manually (Model 1 modular block weigh 39-40 kgs whereas Model 2 block of the present invention weigh 28kgs). In addition, there is significant reduction in carbon emissions due to the savings in concrete. Further, the modular block of the present invention provides more efficient transportation due to lighter weight. Moreover, the production time and effort is reduced by 50% as 2 blocks may be made in a single stroke of the machine as compared to 1 block per stroke, as conventionally performed. This is possible due to the novel structure of the present invention.

EXAMPLE 1
The following example illustrates the invention but is not limiting thereof.
The significant dimensions of the block used were 430 mm length on the front portion (111) and 227mm on the rear portion (113) and a length of 230mm into soil. The height of the blocks is 203mm. Each block having a 16mm high protruding part (120) and area as 59?103mm. The protruding part area to base plan area ratio was 10.5% and the weight of a single block was 28Kg. The connection strength of the present invention is higher by 7% as compared to the prior art. Also the protruding part area to base plan area ratio was 14.1% higher in the modular blocks of the present invention even though the total base area of the block was less than that of the other modular blocks.

INDUSTRIAL APPLICABILITY
It is apparent that the modular block of the present invention has a compact design and provides a strong interconnection mechanism between the modular blocks thereby creatinga robust structure. In addition, the modular block of the present invention is highly economical to produce due to substantial reduction in utilization of concrete materials during production. Further, the light weight modular block address safety concerns and provides effective handling during transportation. Moreover, the light weight modular block increases productivity in creating the structure.

The foregoing description of the invention has been set merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the substance of the invention may occur to person skilled in the art, the invention should be construed to include everything within the scope of the disclosure.
,CLAIMS:
1. A modular block comprising:
a base plan (110); and
a protruding part (120) projecting from a bottom surface (114) of the base plan (110) for interconnecting modular blocks.
2. The modular block as claimed in claim 1, wherein the base plan (110) of the modular block comprises:
a front portion (111);
an extending part (112); and
a rear portion (113).
3. The modular block as claimed in claim 2, wherein the front portion (111) comprises:
a front surface (11101);
a first inclined part (11102, 11103) affixed to the front surface (11101);
a second inclined part (11104, 11105) affixed to the first inclined part (11102, 11103);
a third inclined part (11106, 11107) affixed to the second inclined part (11104, 11105);
a fourth inclined part (11108, 11109) affixed to the third inclined part (11106, 11107); and
a hind surface (11110, 11111) affixed with the fourth inclined part (11108, 11109).
4. The modular block as claimed in claim 2, wherein the extending part (112) has a concave curve (1121, 1122) on opposite sides and interconnects the front portion (111) with the rear portion (113).
5. The modular block as claimed in claim 1, wherein the protruding part (120) extends from the base plan (110) at a height in the range of 13mm to 19mm,preferably 16mm, and has three sloping sides (121, 122, 123) leaving one side straight (124).
6. The modular block as claimed in claim 1, wherein the protruding part (120) extends from the base plan (110) and is located over the front portion (111) and the extending part (112), wherein the sloping sides of the protruding part (121, 122) are structurally matched with the curved sides (1121, 1122) of the extending part.
7. The modular block as claimed in claim 1, wherein the protruding part (120) has a top face (125) such that the area of the top face (125) to the area of the base plan(110) ratio is in the range of 10% to 13%, preferably 10.5%.
8. The modular block as claimed in claim 1, wherein the rear portion (113) comprises:
a first rear surface (1131, 1132);
a curvature part (1133, 1134) affixed to the first rear surface (1131, 1132);
a first inclined part (1135, 1136) affixed to the curvature part (1133, 1134); and
a second rear surface (1137) affixed to the first inclined part (1135, 1136).
9. A modular block system formed with plurality of modular blocks, each having a protruding part and a base plan, wherein the surface area of the protruding part is less than the area of the base plan, such that the lower surface area offered by the protruding part concentrates the force onto a lesser area that results in increased pressure and thereby a high connection value is offered by the modular block system.
10. A modular block structure formed by placing a plurality of modular blocks (210, 220) sideways such that the extending part of any two modular blocks forms a cavity (230), which is optionally filled with industrially acceptable fillers; and at least one other modular block placed over the plurality of modular blocks such that the protruding part of the modular block is locked within the cavity (230).