U.S. patent application number 10/004108 was filed with the patent office on 2003-06-12 for lintel block and method.
This patent application is currently assigned to Steel Block, Inc.. Invention is credited to Gregory, Harbert S., Layne, Harry R..
Application Number | 20030106271 10/004108 |
Document ID | / |
Family ID | 21709181 |
Filed Date | 2003-06-12 |
United States Patent
Application |
20030106271 |
Kind Code |
A1 |
Layne, Harry R. ; et
al. |
June 12, 2003 |
Lintel block and method
Abstract
A modular lintel block includes a rectangular base member, a
first rectangular side member, a second rectangular side member and
a plurality of spacer members. The base member has a first
longitudinal side and a second longitudinal side. The first side
member is coupled to the first longitudinal side of the base
member. The second side member is spaced from the first side member
and is coupled to the second longitudinal side of the base member.
The plurality of spacer members are coupled between the first and
second side members. A method of forming a lintel in a block wall
is provided that includes the steps of constructing the block wall
with an opening using a plurality of construction blocks coupled
together by a cementing slurry. A modular lintel block is installed
and secured into the block wall above the opening with the
cementing slurry.
Inventors: |
Layne, Harry R.; (Covington,
LA) ; Gregory, Harbert S.; (Covington, LA) |
Correspondence
Address: |
SHINJYU GLOBAL IP COUNSELORS, LLP
1233 20TH STREET, NW, SUITE 700
WASHINGTON
DC
20036-2680
US
|
Assignee: |
Steel Block, Inc.
|
Family ID: |
21709181 |
Appl. No.: |
10/004108 |
Filed: |
December 6, 2001 |
Current U.S.
Class: |
52/36.4 |
Current CPC
Class: |
E04C 2003/023 20130101;
E04C 3/02 20130101 |
Class at
Publication: |
52/36.4 |
International
Class: |
E04F 019/00 |
Claims
What is claimed is:
1. An embeddable lintel block comprising: a rectangular base member
having a first longitudinal side and a second longitudinal side; a
first rectangular side member coupled to said first longitudinal
side of said rectangular base member; a second rectangular side
member spaced from said first rectangular side member and coupled
to said second longitudinal side of said rectangular base member;
and a plurality of spacer members coupled between said first and
second rectangular side members.
2. The embeddable lintel block according to claim 1, wherein said
spacer members are configured to form a substantially straight
longitudinal passageway arranged between said first and second
longitudinal side members.
3. The embeddable lintel block according to claim 2, further
comprising a reinforcing bar coupled to said lintel block, said
reinforcing bar being arranged within said longitudinal
passageway.
4. The embeddable lintel block according to claim 1, wherein said
first and second rectangular side members are fixedly coupled to
said first and second longitudinal sides, respectively to form a
substantially U-shaped cross-section.
5. The embeddable lintel block according to claim 1, wherein said
rectangular base member and said first and second rectangular side
members are integrally formed together as a one-piece unitary
member.
6. The embeddable lintel block according to claim 1, wherein each
of said spacers includes a first mounting flange fixedly coupled to
said first longitudinal side member and a second mounting flange
fixedly coupled to said second longitudinal side member.
7. The embeddable lintel block according to claim 1, wherein said
lintel block is constructed of metal.
8. The embeddable lintel block according to claim 1, wherein said
spacer members are fixedly coupled to said first and second
rectangular side members by welding.
9. The embeddable lintel block according to claim 1, wherein said
lintel block has at least four of said spacer members.
10. The embeddable lintel block according to claim 1, wherein said
rectangular base member has a first opening arranged at a first end
of said lintel block and a second opening arranged at a second end
of said lintel block.
11. A method of forming a lintel in a block wall, comprising the
steps of: constructing said block wall with an opening using a
plurality of construction blocks coupled together by a cementing
slurry; installing and securing a modular lintel block into said
block wall above said opening with said cementing slurry, said
modular lintel block having a height and width substantially equal
to a corresponding height and width of said construction blocks,
and a length larger than a corresponding length of one of said
construction blocks, said modular lintel block comprising a
rectangular base member having a first longitudinal side and a
second longitudinal side; a first rectangular side member coupled
to said first longitudinal side of said rectangular base member; a
second rectangular side member spaced from said first rectangular
side member and coupled to said second longitudinal side of said
rectangular base member; and a plurality of spacer members coupled
between said first and second rectangular side members.
12. The method according to claim 11, wherein said length of said
modular lintel block is substantially equal to a predetermined
integer multiple of one-half lengths of said construction
blocks.
13. The method according to claim 11, wherein said spacer members
are configured to form a substantially straight longitudinal
passageway arranged between said first and second longitudinal side
members.
14. The method according to claim 13, wherein a lintel reinforcing
bar is coupled to said modular lintel block within said
longitudinal passageway.
15. The method according to claim 14, wherein said rectangular base
member has a first opening arranged at a first end of said modular
lintel block and a second opening arranged at a second end of said
modular lintel block.
16. The method according to claim 15, further comprising the steps
of: providing first and second wall reinforcing bars; inserting
said first and second wall reinforcing bars in said first and
second openings of said modular lintel block.
17. The method according to claim 11, wherein said rectangular base
member has a first opening arranged at a first end of said modular
lintel block and a second opening arranged at a second end of said
modular lintel block.
18. The method according to claim 17, further comprising the steps
of: providing first and second reinforcing bars; inserting said
first and second wall reinforcing bars in said first and second
openings of said modular lintel block.
19. The method according to claim 11, further comprising the step
of: pouring said cementing slurring into said modular lintel
block.
20. The method according to claim 11, wherein said modular lintel
block includes at least four of said spacer members.
21. The method according to claim 11, wherein said modular lintel
block is constructed of metal.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention generally relates to a lintel block, which is
mounted in a block wall. More specifically, the present invention
relates to an embeddable lintel block, which is permanently secured
or laid within a concrete block or masonry wall during normal
construction to provide a strong lintel in a security facility such
as a jail, prison, juvenile detention center, psychiatric hospital,
etc.
[0003] 2. Background Information
[0004] Many buildings are currently being constructed of concrete
blocks or the like to form a masonry block wall. Moreover, certain
buildings and public facilities, such as jails, prisons, juvenile
detention centers, and psychiatric hospitals, often require the
interior walls to be constructed of concrete blocks. To maximize
security, these types of facilities have wall constructions that
often require the interiors of the blocks to have cement poured
into the cavity or cavities of the wall blocks. These wall
constructions also often require that the cavities have one or more
reinforcing rods extending from the interior of the blocks into the
concrete blocks that are above and below.
[0005] One recent improvement in concrete block walls has been the
use of steel blocks, which is disclosed in U.S. Pat. No. 5,649,391,
issued to Harry R. Layne, on Jul. 22, 1997. This patent discloses a
steel block, which is embedded into the concrete wall. This patent
discloses welding the furniture or accessory to the wall. Moreover,
this patent also teaches having fasteners formed on the steel
block. However, this patent does not teach how to provide lintels
in concrete block walls for mounting above openings in the block
walls.
[0006] Typically, conventional structural beams and concrete
masonry units (U-shaped concrete members) filled with concrete and
reinforced are laid above openings in block walls to support blocks
above the opening, after which steel plates are affixed to the face
of the concrete masonry units so that attachments can be welded to
the face plate. Openings are often needed in block walls for
entries, windows, or other purposes. In many applications, it is
necessary to attach devices to the face or underside of lintels,
such as sliding prison doors, rollup doors and windows. In these
instances concrete masonry block lintels must have steel plate
weldments attached to the face or underside of the concrete masonry
units. Typically, when structural beams are used for lintels, the
structural beams are cut to the desired length and mounted above
the openings. These beams can be difficult to cut. Additionally,
when beams are used for lintels, a steel face plate must be welded
to the beam so as to provide a flat surface for attachment
purposes. These methods are often unattractive and often require
special fitting, plastering and/or patching by the mason when
installed. These procedures can be difficult and time consuming for
the mason, and expensive. Furthermore, it can be difficult to
integrate conventional beams into block walls constructed for
secure facilities such as jails, prisons, juvenile detention
centers, and psychiatric hospitals. In these types of facilities,
construction techniques are often utilized to increase the strength
of the walls. For example, the cinder blocks of these walls are
often filled with cement and vertical reinforcing bars to form a
continuous wall structure, as mentioned above. U-shaped concrete
masonry units and structural steel beams for lintels in detention
areas result in added costs and less desirable prior construction
methodology. Concrete masonry is strong in compression but weak in
tension. This makes it difficult to attach anything to a lintel
made of concrete masonry block units that might be subjected to
vibrations due to external forces. Under such circumstances,
tension in the concrete masonry blocks is unavoidable and failure a
strong possiblity.
[0007] It would be a benefit, therefore, to have an embeddable
lintel block that could be used in connection with a wall that did
not provide a gap between the wall and a mounting surface and that
forms an integral part of the wall construction. It would also be
desirable to have a method for mounting a lintel block permanently
to a concrete block wall that did not require special operations or
skills of the mason.
[0008] In view of the above, there exists a need for a lintel block
which overcomes the above mentioned problems in the prior art. This
invention addresses this need in the prior art as well as other
needs, which will become apparent to those skilled in the art from
this disclosure.
SUMMARY OF THE INVENTION
[0009] One object of the present invention is to provide a lintel
block that can be easily mounted in a concrete block wall, a
masonry wall or a pre-cast concrete wall.
[0010] Another object of the present invention is to provide a
lintel block that will not require additional plastering or
patching of the wall after installation.
[0011] A further object of the present invention is to provide a
lintel block that is very strong, yet relatively simple and
inexpensive to manufacture and assemble, after which, items can be
welded or bolted to the face or underside.
[0012] Yet another object of the present invention is to provide a
lintel block that will fit into the normal confines of the space
occupied by standard masonry blocks in either a horizontal position
or vertical position to eliminate extra fitting by the mason when
the lintel block is installed.
[0013] The new lintel block in accordance with the present
invention is designed to eliminate some of the problems that have
been experienced by the construction industry. The lintel block of
the present invention reduces the cost of installation and provides
a permanently secure and strong lintel with a relatively simple
construction. The lintel block of the present invention allows for
relatively simple attachment of devices to the lintel by welding,
bolts, etc. Preferably, the lintel block is the size of a plurality
of installed full size blocks laid horizontally (end to end) or
vertically (side by side as so-called soldier courses) with
cementing slurry arranged therebetween. Alternatively, the new
lintel block of the present invention has a size that corresponds
to two stacked rows of a predetermined number of installed blocks
of a block wall. In any event, the size of the lintel block
preferably corresponds to the space normally occupied by a
predetermined number of installed blocks or one-half blocks of a
block wall (with or without cementing slurry arranged
therebetween). The predetermined number of blocks defining the size
of the lintel will depend on the size of the blocks, the blocking
arrangement and the desired size and strength of the lintel.
[0014] In accordance with one aspect of the present invention a
lintel block is provided that includes a rectangular base member, a
first rectangular side member, a second rectangular side member and
a plurality of spacer members. The rectangular base member has a
first longitudinal side and a second longitudinal side. The first
rectangular side member is coupled to the first longitudinal side
of the rectangular base member. The second rectangular side member
is spaced from the first rectangular side member and is coupled to
the second longitudinal side of the rectangular base member. The
plurality of spacer members are coupled between the first and
second rectangular side members.
[0015] In the lintel block of the present invention, the spacer
members are preferably configured to form a substantially straight
longitudinal passageway arranged between the first and second
longitudinal side members. A reinforcing bar is preferably coupled
to the lintel block within the longitudinal passageway. The first
and second rectangular side members are preferably fixedly coupled
to the first and second longitudinal sides, respectively to form a
substantially U-shaped cross-section. The rectangular base member
and the first and second rectangular side members are preferably
integrally formed together as a one-piece unitary member. Each of
the spacers preferably includes a first mounting flange fixedly
coupled to the first longitudinal side member and a second mounting
flange fixedly coupled to the second longitudinal side member. The
lintel block is preferably constructed of metal. Preferably, the
lintel block includes at least four spacer members that are fixedly
coupled to the first and second rectangular side members by
welding. The rectangular base member preferably has a first opening
arranged at a first end of the lintel block and a second opening
arranged at a second end of the lintel block.
[0016] In accordance with another aspect of the present invention,
a method of forming a lintel in a block wall is provided that
includes the steps of constructing the block wall with an opening
using a plurality of construction blocks coupled together by a
cementing slurry, and installing and securing a modular lintel
block into the block wall above the opening with the cementing
slurry. The modular lintel block has a height and width
substantially equal to a corresponding height and width of the
construction blocks, and a length larger than a corresponding
length of one of the construction blocks. The modular lintel block
basically includes a rectangular base member, a first rectangular
side member, a second rectangular side member and a plurality of
spacer members. The rectangular base member has a first
longitudinal side and a second longitudinal side. The first
rectangular side member is coupled to the first longitudinal side
of the rectangular base member. The second rectangular side member
is spaced from the first rectangular side member and is coupled to
the second longitudinal side of the rectangular base member. The
plurality of spacer members are coupled between the first and
second rectangular side members.
[0017] In the method of the present invention, the length of the
modular lintel block is preferably substantially equal to a
predetermined integer multiple of one-half lengths of the
construction blocks. The spacer members are preferably configured
to form a substantially straight longitudinal passageway arranged
between the first and second longitudinal side members. A lintel
reinforcing bar is optionally coupled to the modular lintel block
within the longitudinal passageway. The rectangular base member
preferably has a first opening arranged at a first end of the
modular lintel block and a second opening arranged at a second end
of the modular lintel block. Preferably, first and second wall
reinforcing bars are provided and inserted in the first and second
openings of the modular lintel block. The cementing slurring is
preferably poured into the modular lintel block. Preferably, the
modular lintel block includes at least four spacer members and is
constructed of metal.
[0018] These and other objects, features, aspects and advantages of
the present invention will become apparent to those skilled in the
art from the following detailed description, which, taken in
conjunction with the annexed drawings, discloses a preferred
embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Referring now to the attached drawings which form a part of
this original disclosure:
[0020] FIG. 1 is a front perspective view of an embeddable lintel
block in accordance with a preferred embodiment of the present
invention;
[0021] FIG. 2 is a top plan view of the lintel block illustrated in
FIG. 1;
[0022] FIG. 3 is a side elevational view of the lintel block
illustrated in FIGS. 1 and 2;
[0023] FIG. 4 is an enlarged end elevational view of the lintel
block illustrated in FIGS. 1-3;
[0024] FIG. 5 a partial perspective view of the embeddable lintel
block illustrated in FIGS. 1-4 after being partially mounted in a
block wall in accordance with the present invention.
[0025] FIG. 6 a partial perspective view of the embeddable lintel
block illustrated in FIGS. 1-4 after being mounted in a block wall
in accordance with the present invention.
[0026] FIG. 7 is a front perspective view of a modified embeddable
lintel block in accordance with another preferred embodiment of the
present invention;
[0027] FIG. 8 is a top plan view of the lintel block illustrated in
FIG. 7;
[0028] FIG. 9 is a side elevational view of the lintel block
illustrated in FIGS. 7 and 8;
[0029] FIG. 10 is an enlarged end elevational view of the lintel
block illustrated in FIGS. 7-9;
[0030] FIG. 11 is a front perspective view of a modified embeddable
lintel block in accordance with yet another preferred embodiment of
the present invention;
[0031] FIG. 12 is a top plan view of the lintel block illustrated
in FIG. 11;
[0032] FIG. 13 is a side elevational view of the lintel block
illustrated in FIGS. 11 and 12; and
[0033] FIG. 14 is an enlarged end elevational view of the lintel
block illustrated in FIGS. 11-13.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Referring initially to FIGS. 1-4, an embeddable lintel or
lintel block 10 is illustrated in accordance with one embodiment of
the present invention. The lintel block 10 basically includes a
rectangular base member 12, a pair of generally rectangular side
members 14 and 16 and a plurality of spacer members 18. Preferably,
these members are all constructed of metal plates fixedly coupled
together to form an elongated unitary metal unit. The members 12,
14, 16 and 18 are preferably fixedly coupled together by welding,
other conventional metal fastening means and/or constructed
together as a unitary member or members, as discussed below. Of
course, the lintel block 10 could be constructed of other materials
if needed and/or desired.
[0035] As seen in FIGS. 5 and 6, the embeddable lintel block 10 is
embedded within a block wall 11 constructed of construction blocks
13 such as cinder blocks, concrete blocks or masonry blocks. The
embeddable lintel block 10 is designed to be grouted just like the
construction blocks 13 (i.e. cinder blocks, concrete blocks or
masonry blocks). Thus, the lintel block 10 fits into the normal
confines of the space occupied by a plurality of standard
construction blocks in either a horizontal position or vertical
position to eliminate extra fitting by the mason as the lintel
block 10 is installed.
[0036] Referring again to FIGS. 1-4, the embeddable lintel block 10
is preferably an elongated rectangular modular block that is sized
to fit in a space normally occupied by a plurality of the
construction blocks 13. More specifically, in the illustrated
embodiment, the embeddable lintel block 10 is sized to fit in a
space normally occupied by a plurality cinder blocks, concrete
blocks or masonry blocks (i.e. utilized as the construction blocks
13 in the illustrated embodiment). As seen in FIG. 1, the
embeddable lintel block 10 has a height or width "A", a length "B"
and a depth or width "C". The height "A" is preferably between
about seven inches and seventeen inches (i.e. between the height of
a single standard concrete block and the height of a pair of
stacked installed standard concrete blocks) in the illustrated
embodiment.
[0037] The lintel block 10 could have a height "A" corresponding to
the length of an installed standard concrete block (i.e. if
standard blocks are positioned vertically, side by side as
so-called soldier courses). The length "B" is preferably between
about forty-two inches and about eighty inches for a lintel block
10 having a height "A" of a singled standard concrete block. Of
course, the length "B" could be longer than eighty inches if needed
and/or desired, as long as the lintel block 10 has sufficient
strength. For example, in a lintel block 10 longer than eighty
inches (i.e. up to about one-hundred-thirteen inches), the height
"A" should be increased to the height of a pair of stacked
installed standard concrete blocks (about fifteen and five-eighths
inches). In any event, the length "B" preferably corresponds to the
length of a predetermined number of installed standard concrete
(cinder) blocks mounted either vertically or horizontally.
[0038] More specifically, in the illustrated embodiment, the lintel
block 10 preferably has a height "A" of approximately seven and
five-eighths (75/8") inches, a length "B" of approximately
sixty-seven (67") inches and a depth "C" of approximately seven and
five-eighths (75/8") inches. This size of block 10 allows the block
to completely fill the space normally occupied by a row of
horizontal cinder blocks, concrete blocks or masonry blocks
(installed in a wall). While the embeddable lintel block 10 is
illustrated with a single block height (i.e. the height "A" the
size of one cinder block), it will be apparent to those skilled in
the art from this disclosure that the lintel block 10 can have
other sizes as needed and/or desired. For example, lintel block 10
could be constructed to have a height of a double block (i.e. the
height "A" the size of two stacked cinder blocks, or a vertical
cinder block), or any suitable size as needed and or desired. Of
course, the dimensions of the lintel block 10 will depend on the
size of the construction blocks used in the wall, the size of the
opening and the mortaring procedures used in constructing the wall.
The size of the lintel block 10 will also depend on the desired
strength of the lintel and the blocking arrangement used in
constructing the block wall.
[0039] In any event, the lintel block 10 is preferably a modular
lintel block that has a height "A" and width "C" substantially
equal to a corresponding height and width of the construction
blocks 13 of the block wall 11, and a length "B" larger than a
corresponding length of one of the construction blocks 13 of the
block wall. The length "B" of the modular lintel block 10 is
preferably substantially equal to a predetermined integer multiple
of one-half lengths of the construction blocks 13. Thus, the height
"A", length "B" and width/depth "C" depend on the type of
construction blocks 13 utilized in the block wall 11. In other
words, the length "B" of the modular lintel block 10 preferably
corresponds to the length of a predetermined number of construction
blocks 13 or a predetermined number of blocks 13 plus one-half of
one block 13. Moreover, the length "B" can correspond to
substantially the exact length of the predetermined number of
blocks 13 mounted horizontally or vertically (plus optionally a
one-half block), or be slightly longer to account for spacing
between the construction blocks 13.
[0040] It will be apparent to those skilled in the art from this
disclosure that the members 12, 14, 16 and 18 can be constructed as
single separate members or of several plates which are fixedly
secured together by suitable means such as welding. Moreover, it
will be apparent to those skilled in the art from this disclosure
that some or all of these plate members 12, 14, 16 and 18 can be
constructed from a single plate which is bent to form two or more
of the metal plate members. For example, the rectangular base
member 12 and the first and second rectangular plate members 14 and
16 can be integrally formed by bending a single metal plate into a
U-shaped member, or formed of three separate plates welded
together. Thus, it is relatively easy to attach other devices such
as doors or windows to the flat surfaces of the lintel block 10 by
welding, bolts, etc.
[0041] In the illustrated embodiment, the rectangular base member
12 and the first and second rectangular side members 14 and 16 are
preferably constructed of one-quarter (1/4") inch mild steel plates
(ASTM A-36) and have thicknesses, which are substantially equal to
each other. However, lesser/higher gauges of steel can be used if
applicable. The first and second rectangular side members 14 and 16
each have a height "A" of about seven and five-eighths (7{fraction
(5/8)}") inches and a length "B" of about sixty-seven (67") inches.
The depth "C" of block 10 is preferably about seven and
five-eighths (75/8 ) inches, as mentioned above. Thus, the
rectangular base member 12 preferably has a width of approximately
seven and five-eighths (75/8") inches and a length of about
sixty-seven (67") inches.
[0042] In the illustrated embodiment, rounded corners are formed
between the base member 12 and the first and second side members 14
and 16. In the illustrated embodiment, the base member 12 and first
and second side members 14 and 16 are preferably formed by bending
a single flat sheet of one-quarter (1/4") inch mild steel plate
(ASTM A-36). Thus, in the illustrated embodiment, the base member
12 and the first and second side members 14 and 16 are preferably
integrally formed together as a one-piece, unitary member with a
substantially U-shaped cross-section. The rounded corners can be
considered part of the base member 12 and/or the side members 14
and 16. In any event, the lintel block 10 preferably has a total
height "A" of approximately seven and five-eighths (75/8") inches,
a total length "B" of approximately sixty-seven (67") inches and a
total depth "C" of approximately seven and five-eighths (75/8")
inches. Of course, this is the preferable size when the lintel
block 10 is utilized in a wall of standard cinder blocks, concrete
blocks or masonry blocks.
[0043] The first and second rectangular side members 14 and 16 are
preferably metallic planar plate members, which are secured
together by the rectangular base member 12 and the spacer members
18 so as to be spaced a predetermined distance apart from each
other. The spacer members 18 hold the first and second rectangular
metal plate members 14 and 16 substantially parallel to each other
and reinforce the lintel block 10. Moreover, in the illustrated
embodiment, the spacer members 18 are preferably substantially
parallel to each other. Additionally, as seen in FIG. 2 (in broken
phantom lines), a plurality of two (2") inch pieces of Styrofoam 17
can optionally be arranged adjacent the second side member 16. A
plurality of concrete or cement receiving cavities are formed
between the first and second rectangular side members 14 and 16 and
the spacer members 18. Each spacer member 18 preferably includes a
central square cutout 20 to reduce the weight of the spacer members
18 and to allow fluid communication between the cement receiving
cavities. Moreover, the spacer members 18 (with the cutouts 20) are
configured to form a substantially straight longitudinal passageway
arranged between the first and second longitudinal side members 14
and 16.
[0044] Of course, it will be apparent to those skilled in the art
that the first and second rectangular side members 14 and 16 could
be formed separately from the base member 12 using alternative
manufacturing techniques. For example, the base member 12 and the
first and second side members 14 and 16 could be formed as flat
plates welded together in a conventional manner. Alternatively, the
base member 12 and the first and second side members 14 and 16
could be configured to be coupled together by rivets or bolts. In
any event, the base member 12 and the first and second side members
14 and 16 should be configured to form a fluid-tight seal for the
lintel block 10.
[0045] The base member 12 preferably includes a pair of openings
22a and 22b formed therein, with the opening 22a arranged at one
end of the of the base member 12 and the other opening 22b arranged
at the opposite end of the base member 12. Each of the openings 22a
and 22b is preferably a four (4") square opening designed to
receive a vertical reinforcing bar therethrough, as discussed below
in more detail. The openings 22a and 22b are also designed to allow
cement to flow downwardly into blocks arranged below. The openings
22a and 22b are preferably spaced about two (2") inches from the
respective ends of the lintel block 10. In other words, the lintel
block 10 is preferably arranged above an opening O formed in the
block wall 11 and is longer than the opening O so that the openings
22a and 22b are at least partially aligned with cement receiving
cavities of the blocks of the wall, as discussed below.
[0046] The spacer members 18 are preferably constructed from ten
gauge mild steel plate (ASTM A-36). The spacer members 18 can have
roughly the same height or a smaller height than the first and
second rectangular plate members 14 and 16. In the illustrated
embodiment, each of the spacer members 18 have a height of about
six and five-eighths (65/8") inches. In other words, the spacer
members 18 are preferably about one (1") inch shorter than the
height "A" of the lintel block 10. Preferably the top of each
spacer 18 is spaced about one-half (1/2") inch from the tops of the
first and second side members 14 and 16, while the bottom of each
spacer member 18 is spaced about one-quarter (1/4") inch from the
base member 12. Thus, a 1/4" rectangular longitudinal passageway is
also formed below the spacer members 18 adjacent the base member
12. Of course, the height of the spacer members 18 can vary if
needed and/or desired. Thus, it will be apparent to those skilled
in the art from this disclosure that a reinforcing bar could
optionally be arranged between the spacer members 18 and the base
member 12 if needed and/or desired.
[0047] Each spacer member 18 preferably includes a base portion 28
with a pair of bent end flanges 30 and 32 extending from opposite
sides of the base portion 28. In the illustrated embodiment, the
bent end flange 30 or 32 coupled to the first side member 14 will
be considered a first mounting flange while the bent end flange 30
or 32 coupled to the second side member 16 will be considered a
second mounting flange. The hole or cutout 20 is formed in the base
portion 28 of each spacer 18 and is preferably a three and one-half
(31/2") inch centrally located square cutout. Each end flange 30
and 32 is preferably welded to one of the first and second side
plates 14 and 16. Each of the spacer members 18 is preferably
formed as a one-piece unitary metal member by bending a rectangular
plate.
[0048] In the illustrated embodiment, the lintel block 10
preferably has seven (7) identical spacer members 18. Preferably,
the spacer members 18 are arranged along the entire length of the
lintel block 10, with four of the spacer members 18 arranged in a
first orientation and three of the spacer members 18 arranged in a
second opposite orientation. Specifically, the bent end flanges 30
and 32 of four of the spacer members 18 extend in a first
direction, while the bent end flanges 30 and 32 of three of the
spacer members 18 extend in a second direction opposite from the
first direction, as seen in FIGS. 1-3. The spacer members 18
arranged at the ends of the lintel block 10 face inwardly so that
their base portions 28 are aligned with the ends of the lintel
block. Preferably, the spacer members 18 are substantially equally
spaced along the length of the lintel block 10. Of course, it will
be apparent to those skilled in the art from this disclosure that
the lintel block 10 could utilize more/fewer spacers 18 if needed
and/or desired. However, preferably, the lintel block 10 has at
least four of the spacer members 18.
[0049] Of course, it will be apparent to those skilled in the art
from this disclosure that each spacer member 18 could be
constructed of several pieces or have different structures without
departing from the scope of the present invention. For example,
each spacer member could be formed of a pair of spacing straps to
form an opening therebetween. In any event, the spacer members 18
are configured to form at least one longitudinal axial through
passageway for receiving cement and/or a reinforcing bar. In other
words, a (horizontal) reinforcing bar can optionally be mounted
within the longitudinal passageway formed by the cutouts 20. The
reinforcing rod can be welded within the cutouts 20 during
fabrication of the lintel block 10 or laid within the cutouts 20
during installation of the lintel block 10 (and then optionally
secured to the lintel block 10). Of course, it will be apparent to
those skilled in the art from this disclosure that such a
reinforcing bar could be secured to the lintel block 10 utilizing
any suitable attachment technique without departing from the scope
of the present invention. It will also be apparent to those skilled
in the art from this disclosure that the spacers do not have to be
identical, if needed and/or desired.
[0050] Alternatively, each spacer member 18 can have an additional
cutout (not shown in this embodiment) formed therein and arranged
at the bottom edge for receiving cement and/or a reinforcing bar as
discussed below in reference to another preferred embodiment of the
present invention. Additionally, a J-shaped bar support member can
optionally be coupled to each spacer, as also discussed below in
reference to another preferred embodiment of the present invention.
Alternatively, the reinforcing bar can be welded to the spacers, as
also discussed below.
[0051] Construction of lintel block 10 will now be discussed in
more detail. As mentioned above, the rectangular base member 12 and
the first and second rectangular side members 14 and 16, and the
spacers 18 are preferably bent and welded together, respectively,
to be fixedly coupled together in a conventional manner. More
specifically, a plate is preferably bent to form the rectangular
base member 12 and the first and second rectangular side members 14
and 16. The spacers 18 are preferably welded to the first and
second rectangular side members 14 and 16 via the end flanges 30
and 32 in a relatively conventional manner.
[0052] Of course, it will be apparent to those skilled in the art
that spacer members 18 could have other configurations, and could
be fixedly coupled to the first and second rectangular side members
14 and 16 by other conventional mounting methods (such as rivets,
bolts, etc), without departing from the scope of the present
invention. However, the spacers 18 are preferably welded to the
first and second rectangular side members 14 and 16 to create an
extremely strong, secure lintel block 10.
[0053] Referring again to FIGS. 5 and 6, a perspective view of a
partially constructed concrete block wall 11 is illustrated. Block
wall 11 is constructed from a plurality of conventional blocks 13
such as cinder blocks, concrete blocks or masonry blocks. Each of
the blocks 13 includes a pair of cement receiving cavities 13a. The
lintel block 10 is shown installed between the concrete blocks 13
and above the opening O so that the lintel block 10 becomes an
integral part of concrete block wall 11. Additional rows of
concrete blocks 13 can then be installed above the lintel block 10
without significantly reducing the strength of the block wall
11.
[0054] An exemplary method of forming a lintel in a concrete block
wall 11 will now be described. In this exemplary method of
permanently attaching and embedding the lintel block 10 into the
concrete block wall 11, the method includes the step of installing
at least one lintel block 10, as described above, into the concrete
block wall 11 in place of a plurality of the blocks 13 during
construction of the concrete block wall 11. Installation of lintel
block 10 is as follows. First, the cinder, concrete or masonry
blocks 13 are laid down to begin construction of the concrete wall.
The concrete block wall 11 is constructed with the opening O using
a plurality of concrete blocks 13 coupled together by a cementing
slurry C. The lintel block 10 is installed and secured into the
concrete block wall 11 above the opening O with the cementing
slurry C. The term "cementing slurring" as used herein means any
suitable paste or attachment material that does not necessarily
include concrete as an ingredient.
[0055] The cementing slurring C is preferably poured into the
lintel block and flows through the openings 22a and 22b into the
concrete blocks 13 located below. Preferably, (first and second)
vertical wall reinforcing bars R are inserted into the openings 22a
and 22b of the lintel block 10. Optionally, a horizontal
reinforcing bar similar to reinforcing bar R (not shown in this
embodiment) can be arranged in the longitudinal passageway formed
by the cutouts 20 of the spacer members 18, as discussed above.
Reinforcing bars such as the reinforcing bar R or the optional
horizontal reinforcing bar are relatively well known in the art.
Thus, the exact size and/or material of the reinforcing bar R will
not be discussed and/or illustrated in detail herein. Rather, it
will be apparent to those skilled in the art from this disclosure
that any suitable size and/or material could be utilized for the
reinforcing bar R or the optional horizontal reinforcing bar.
[0056] In other words, the lintel block 10 is placed unto the
cinder, concrete or masonry blocks 13 of the concrete wall 11 in a
desired location of the opening O. The openings 22a and 22b are at
least partially aligned with the cement receiving cavities of the
cinder, concrete or masonry blocks 13. The vertical reinforcing
bars R are placed through the openings 22a and 22b and the
cementing slurry mixture C is poured into the lintel block 10. Of
course, the block wall 11 can be constructed without reinforcing
bars B. However, the reinforcing bars R add extra strength and
security to the block wall 11. In other words, in some applications
the cementing slurry C can provide adequate strength and reduced
costs. However, the reinforcing bars R are preferred in order to
provide an extremely strong, secure block wall 11.
Second Embodiment--Modified Lintel Block
[0057] Referring now to FIGS. 7-10, a modified lintel block 110 is
illustrated in accordance with a second preferred embodiment of the
present invention. The lintel block 110 is identical to lintel
block 10, except that lintel block 110 includes spacers 118 having
additional cutouts 121 with a reinforcing bar R' mounted therein.
The remaining parts of the spacer members 118 are identical to the
first embodiment. All of the spacer members 118 are identical to
each other in this embodiment although four of the spacer members
118 are oriented in a first direction while three of the spacer
members 118 are oriented in a second direction opposite the first
direction. The remaining components or parts of the lintel block
110 are identical to the parts of the lintel block 10 and have the
same function of the corresponding components or parts of the
lintel block 10. In view of the similarities between this modified
lintel block 110 and the lintel block 10, the similar parts of the
lintel block 110 will not be discussed and/or illustrated in detail
herein. Rather, the following description will focus mainly on the
differences. Moreover, the explanations of components or parts and
the operations of this second embodiment that are similar to
components or parts and the operations of the first embodiment will
be omitted.
[0058] The lintel block 110 basically includes a rectangular base
member 112, a pair of generally rectangular side members 114 and
116 and the plurality of spacer members 118. The members 112, 114
and 116 are identical to the members 12, 14 and 16 of the first
embodiment. Moreover, the lintel block 110 is constructed in a
manner substantially identical to the first embodiment, except for
the additional step of mounting the reinforcing bar R' in the
additional cutouts 121 of the modified spacer members 118.
Specifically, the reinforcing bar R' is preferably a metal bar that
is welded within the cutouts 121 of the spacer members 118 after
the members 112, 114, 116 and 118 are bent and coupled together,
respectively. The additional cutouts 121 are arranged to be
adjacent the base member 112, such that the reinforcing bar R'
located in the additional cutouts 121 provides added strength for
the lintel block 110. In other words, the spacer members 118 (with
the additional cutouts 121) are configured to form an additional
substantially straight longitudinal passageway for receiving the
reinforcing bar R'. The lintel block 110 is designed to be mounted
in the block wall 11 by the method described in the first
embodiment except as modified above.
[0059] Of course, it will be apparent to those skilled in the art
from this disclosure that the reinforcing bar R' could be
constructed of any suitable material and/or size, as needed and/or
desired. Moreover, it will be apparent to those skilled in the art
from this disclosure that the reinforcing bar R' could be utilized
in the longitudinal passageway of the lintel block 10 of the first
embodiment.
Third Embodiment--Modified Lintel Block
[0060] Referring now to FIGS. 11-14, a modified lintel block 210 is
illustrated in accordance with a third preferred embodiment of the
present invention. The lintel block 210 is identical to lintel
block 10, except that lintel block 210 includes spacer members 218
that have additional cutouts 221 and support members 223. The
remaining parts of the spacer members 218 are identical to the
first embodiment. All of the spacer members 218 are identical
although four spacer members 218 are oriented in a first direction
while three of the spacer members 218 are oriented in a second
direction opposite the first direction. A reinforcing bar R" is
preferably metal and is mounted in the cutouts 221 and supported by
the support members 223. The reinforcing bar R" is not welded to
the spacer members 218 within the additional cutouts 221 in this
third embodiment. In other words, this embodiment is a modified
version of the second embodiment. The remaining components or parts
of the lintel block 210 are identical to the parts of the lintel
blocks 10 and 110, and have the same function of the corresponding
components or parts of the lintel blocks 10 and 110. In view of the
similarities between this modified lintel block 210 and the lintel
blocks 10 and 110, the similar parts of the lintel block 210 will
not be discussed and/or illustrated in detail herein. Rather, the
following description will focus mainly on the differences.
Moreover, the explanations of components or parts and the
operations of this third embodiment that are similar to components
or parts and the operations of the first and second embodiments
will be omitted.
[0061] The lintel block 210 basically includes a rectangular base
member 212, a pair of generally rectangular side members 214 and
216 and the plurality of spacer members 218. The members 212, 214
and 216 are identical to the members 12, 14 and 16 of the first
embodiment. Moreover, the lintel block 210 is constructed in a
manner substantially identical to the first embodiment, except for
the additional steps of fixedly coupling the support members 223 to
the spacer members 218 and mounting the reinforcing bar R" in the
additional cutouts 221 to be supported on the support members 223.
Specifically, the support members 223 are preferably J-shaped metal
plate members that are welded to the spacer members 218 prior to
coupling the spacer members 218 to the first and second side
members 214 and 216. The reinforcing bar R" is then removably
mounted on the support members 223 within the additional cutouts
221. The additional cutouts 221 are arranged to be adjacent the
base member 212 (i.e. identical to the second embodiment), such
that the reinforcing bar R" located in the additional cutouts 221
provides added strength for the lintel block 210. Thus, in this
embodiment, the reinforcing bar R" is optional. In other words, the
spacer members 218 (with the additional cutouts 221) are configured
to form an additional substantially straight longitudinal
passageway for optionally receiving the reinforcing bar R". The
lintel block 210 is also designed to be mounted in the block wall
11 by the method described in the first embodiment except as
modified above.
[0062] Of course, it will be apparent to those skilled in the art
from this disclosure that the reinforcing bar R" could be
constructed of any suitable material and/or size, as needed and/or
desired. Moreover, it will be apparent to those skilled in the art
from this disclosure that the reinforcing bar R" could be utilized
in the longitudinal passageway of the lintel block 10 of the first
embodiment.
[0063] The terms of degree such as "substantially", "about" and
"approximately" as used herein mean a reasonable amount of
deviation of the modified term such that the end result is not
significantly changed. These terms should be construed as including
a deviation of at least .+-.5% of the modified term if this
deviation would not negate the meaning of the word it modifies.
[0064] While only selected embodiments have been chosen to
illustrate the present invention, it will be apparent to those
skilled in the art from this disclosure that various changes and
modifications can be made herein without departing from the scope
of the invention as defined in the appended claims. Furthermore,
the foregoing description of the embodiments according to the
present invention are provided for illustration only, and not for
the purpose of limiting the invention as defined by the appended
claims and their equivalents.
* * * * *