U.S. patent application number 11/495481 was filed with the patent office on 2007-02-01 for open ended interlocking block system.
Invention is credited to Juan Haener.
Application Number | 20070022684 11/495481 |
Document ID | / |
Family ID | 37684010 |
Filed Date | 2007-02-01 |
United States Patent
Application |
20070022684 |
Kind Code |
A1 |
Haener; Juan |
February 1, 2007 |
Open ended interlocking block system
Abstract
An interlocking block system building system for block walls
which employs an "H" shaped open ended block to build any size
walled structure. The device features a first block having a center
portion connecting and two parallel sidewalls with two open ends
opposite the endwalls. A plurality of interlocking tabs projecting
from the top surface of the blocks engage with receptors in blocks
stacked above. Projections and recesses formed on the distal edges
of the blocks are adapted to engage with projections and recesses
formed on the endwalls of adjacent blocks in a wall. The distal
edge engagements may be translated to allow for adjustment of block
spacing and ultimate wall size.
Inventors: |
Haener; Juan; (San Diego,
CA) |
Correspondence
Address: |
DONN K. HARMS;PATENT & TRADEMARK LAW CENTER
SUITE 100
12702 VIA CORTINA
DEL MAR
CA
92014
US
|
Family ID: |
37684010 |
Appl. No.: |
11/495481 |
Filed: |
July 27, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60703636 |
Jul 28, 2005 |
|
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|
Current U.S.
Class: |
52/286 |
Current CPC
Class: |
E04B 2002/0206 20130101;
E04B 2/54 20130101; E04B 2002/0226 20130101; E04B 2002/0215
20130101 |
Class at
Publication: |
052/286 |
International
Class: |
E04B 1/00 20060101
E04B001/00; E04B 5/00 20060101 E04B005/00 |
Claims
1. An interlocking block system for use in construction of a: wall
comprising: an H-shaped block having a pair of generally
rectangular, parallel, first and second sidewalls; each of said
sidewalls having a top portion with substantially flat upper
surfaces and each having a bottom portion with substantially flat
lower surfaces; each of said sidewalls having first distal edges on
one end defining a first pair of distal edges and having a second
distal edges on a second end defining a second pair of distal edges
with said first and second pair of distal edges substantially
equidistant from a center of said block; each of said sidewalls
having an internal and an external surface extending between said
upper surfaces and said lower surfaces; a central portion of said
block communicating between said internal surfaces of said
sidewalls and having two opposing side surfaces on opposite sides
of said center; a pair of cavities defined by the areas between
opposing side surfaces of said central portion, said infernal
surfaces of said sidewalls, and open areas extending between said
distal edges of said sidewalls; means to interlock said first pair
of distal edges of any one said block in an engagement with said
second pair of distal edges of any adjacently located said block
whereby a layer of a plurality of said blocks with coplanar
sidewalls and engaged distal edges can be formed; and means to
interlock said top portion of any underlying said block with said
bottom portion of any overlaid said block placed thereon with its
sidewalls coplanar and with either of its said first pair of distal
edges or said second pair of distal edges substantially at said
center of said underlying said block.
2. The interlocking block system of claim 1 additionally
comprising: said blocks forming a wall; said blocks forming said
wall engaged in overlaid individual layers upon underlying
individual layers, each of said individual layers formed of
adjacent said blocks engaged at their respective first and second
pairs of distal edges; and each said overlaid layer supported on an
underlying said individual with their respective sidewalls coplanar
and with one of said first pair of distal edges or said second pair
of distal edges of each overlaid layer substantially at said center
of a said block in said underlying individual layer.
3. The interlocking block system of claim 1 wherein said means to
interlock said first pair of distal edges of any one said block in
an engagement with said second pair of distal edges of any
adjacently located said block comprises: a projection extending
from one of said first pair and one of said second pair of distal
edges; a recess formed in the other of said first pair and one of
said second pair of distal edges; and said projections adapted for
engagement in said recess.
4. The interlocking block system of claim 3 additionally
comprising: said projections being tapered from a widest point
adjacent to said respective distal end to a narrowest point at a
distal end of said projection.
5. The interlocking block system of claim 4 additionally
comprising: said recesses being tapered to receive said tapered
projections.
6. The interlocking block system of claim 1 wherein said means to
interlock said top portion of any underlying said block with said
bottom portion of any overlaid said block comprises: a first pair
of inwardly extending ridges running generally perpendicular to
said top surfaces of said sidewalls, one of said first pair running
along said inner surface of said first sidewall and the other of
said first pair running along said inner surface of said second
sidewall; a second pair of inwardly extending ridges running
generally perpendicular to said top surfaces of said sidewalls, one
of said second pair running along said inner surface of said first
sidewall and the other of said second pair running along said inner
surface of said second sidewall; said first and second pair of
ridges being substantially equidistant from said center of said
block; all four of said ridges including ridge pin portions
extending beyond said upper surfaces of said first and second
sidewalls respectively; and said ridge pins having a first side
surface substantially coplanar with the interior surface of the
respective said sidewall from which it extends, whereby said first
side surfaces, of said first pair or second pair of ridges, will
frictionally engage with respective inner surfaces of said
sidewalls in one of said pair of cavities in a said block overlaid
thereon.
7. The interlocking block system of claim 3 wherein said means to
interlock said top portion of any underlying said block with said
bottom portion of any overlaid said block comprises: a first pair
of inwardly extending ridges running generally perpendicular to
said top surfaces of said sidewalls, one of said first pair running
along said inner surface of said first sidewall and the other of
said first pair running along said inner surface of said second
sidewall; a second pair of inwardly extending ridges running
generally perpendicular to said top surfaces of said sidewalls, one
of said second pair running along said inner surface of said first
sidewall and the other of said second pair running along said inner
surface of said second sidewall; said first and second pair of
ridges being substantially equidistant from said center of said
block; all four of said ridges including ridge pin portions
extending beyond said upper surfaces of said first and second
sidewalls respectively; and said ridge pins having a first side
surface substantially coplanar with the interior surface of the
respective said sidewall from which it extends, whereby said first
side surfaces, of said first pair or second pair of ridges, will
frictionally engage with respective inner surfaces of said
sidewalls in one of said pair of cavities in a said block overlaid
thereon.
8. The interlocking block system of claim 4 wherein said means to
interlock said top portion of any underlying said block with said
bottom portion of any overlaid said block comprises: a first pair
of inwardly extending ridges running generally perpendicular to
said top surfaces of said sidewalls, one of said first pair running
along said inner surface of said first sidewall and the other of
said first pair running along said inner surface of said second
sidewall; a second pair of inwardly extending ridges running
generally perpendicular to said top surfaces of said sidewalls, one
of said second pair running along said inner surface of said first
sidewall and the other of said second pair running along said inner
surface of said second sidewall; said first and second pair of
ridges being substantially equidistant from said center of said
block; all four of said ridges including ridge pin portions
extending beyond said upper surfaces of said first and second
sidewalls respectively; and said ridge pins having a first side
surface substantially coplanar with the interior surface of the
respective said sidewall from which it extends, whereby said first
side surfaces, of said first pair or second pair of ridges, will
frictionally engage with respective inner surfaces of said
sidewalls in one of said pair of cavities in a said block overlaid
thereon.
9. The interlocking block system of claim 5 wherein said means to
interlock said top portion of any underlying said block with said
bottom portion of any overlaid said block comprises: a first pair
of inwardly extending ridges running generally perpendicular to
said top surfaces of said sidewalls, one of said first pair running
along said inner surface of said first sidewall and the other of
said first pair running along said inner surface of said second
sidewall; a second pair of inwardly extending ridges running
generally perpendicular to said top surfaces of said sidewalls, one
of said second pair running along said inner surface of said first
sidewall and the other of said second pair running along said inner
surface of said second sidewall; said first and second pair of
ridges being substantially equidistant from said center of said
block; all four of said ridges including ridge pin portions
extending beyond said upper surfaces of said first and second
sidewalls respectively; and said ridge pins having a first side
surface substantially coplanar with the interior surface of the
respective said sidewall from which it extends, whereby said first
side surfaces, of said first pair or second pair of ridges, will
frictionally engage with respective inner surfaces of said
sidewalls in one of said pair of cavities in a said block overlaid
thereon.
10. The interlocking block system of claim 6 additionally
comprising: said first pair of inwardly extending ridges having a
first engagement surface, generally traverse to said inner surface
and adjacent to said bottom portion of said block; said second pair
of inwardly extending ridges having a second engagement surface,
generally traverse to said inner surface and adjacent to said
bottom portion of said block; said first engagement surface and
said second engagement surfaces being substantially equidistant
from said center and spaced from each other by a first distance;
all four of said pin portions having a second side surface running
a direction traverse to said first side surface; said second side
surfaces of said ridge pins extending from said first pair of
ridges being distanced from said second side surface of said ridge
pins extending from said second pair of ridges a second distance
slightly less than said first distance; and whereby an overlaid
said block placed upon two underling coplanar said blocks with
their distal edges engaged substantially at said center of said
overlaid block, will accommodate translation of said underling
blocks a distance equal to the difference between said first
distance and said second distance providing means of adjustment of
the total length of a wall.
11. The interlocking block system of claim 7 additionally
comprising: said first pair of inwardly extending ridges having a
first engagement surface, generally traverse to said inner surface
and adjacent to said bottom portion of said block; said second pair
of inwardly extending ridges having a second engagement surface,
generally traverse to said inner surface and adjacent to said
bottom portion of said block; said first engagement surface and
said second engagement surfaces being substantially equidistant
from said center and spaced from each other by a first distance;
all four of said pin portions having a second side surface running
a direction traverse to said first side surface; said second side
surfaces of said ridge pins extending from said first pair of
ridges being distanced from said second side surface of said ridge
pins extending from said second pair of ridges a second distance
slightly less than said first distance; and whereby an overlaid
said block placed upon two underling coplanar said blocks with
their distal edges engaged substantially at said center of said
overlaid block, will accommodate translation of said underling
blocks a distance equal to the difference between said first
distance and said second distance providing means of adjustment of
the total length of a wall.
12. The interlocking block system of claim 8 additionally
comprising: said first pair of inwardly extending ridges having a
first engagement surface, generally traverse to said inner surface
and adjacent to said bottom portion of said block; said second pair
of inwardly extending ridges having a second engagement surface,
generally traverse to said inner surface and adjacent to said
bottom portion of said block; said first engagement surface and
said second engagement surfaces being substantially equidistant
from said center and spaced from each other by a first distance;
all four of said pin portions having a second side surface running
a direction traverse to said first side surface; said second side
surfaces of said ridge pins extending from said first pair of
ridges being distanced from said second side surface of said ridge
pins extending from said second pair of ridges a second distance
slightly less than said first distance; and whereby an overlaid
said block placed upon two underling coplanar said blocks with
their distal edges engaged substantially at said center of said
overlaid block, will accommodate translation of said underling
blocks a distance equal to the difference between said first
distance and said second distance providing means of adjustment of
the total length of a wall.
13. The interlocking block system of claim 9 additionally
comprising: said first pair of inwardly extending ridges having a
first engagement surface, generally traverse to said inner surface
and adjacent to said bottom portion of said block; said second pair
of inwardly extending ridges having a second engagement surface,
generally traverse to said inner surface and adjacent to said
bottom portion of said block; said first engagement surface and
said second engagement surfaces being substantially equidistant
from said center and spaced from each other by a first distance;
all four of said pin portions having a second side surface running
a direction traverse to said first side surface; said second side
surfaces of said ridge pins extending from said first pair of
ridges being distanced from said second side surface of said ridge
pins extending from said second pair of ridges a second distance
slightly less than said first distance; and whereby an overlaid
said block placed upon two underling coplanar said blocks with
their distal edges engaged substantially at said center of said
overlaid block, will accommodate translation of said underling
blocks a distance equal to the difference between said first
distance and said second distance providing means of adjustment of
the total length of a wall.
14. The interlocking block system of claim 1 additionally
comprising: a pathway communicating between all said overlaid
blocks and any portions of any said underlying blocks; and said
pathway formed between the sidewalls of all overlaid and underlying
blocks by portions of said pair of cavities of each overlaid block,
communicating with lower portions of cavities of underlying blocks;
whereby cementitious material may be poured into the pathway
communicating with said top surface of an uppermost said overlaid
block, and communicate to said cavity of a lowest said underlying
block which communicates with said pathway passageway.
15. The interlocking block system of claim 2 additionally
comprising: a pathway communicating between all said overlaid
blocks and any portions of any said underlying blocks; and said
pathway formed between the sidewalls of all overlaid and underlying
blocks by portions of said pair of cavities of each overlaid block,
communicating with lower portions of cavities of underlying blocks;
whereby cementitious material may be poured into the pathway
communicating with said top surface of an uppermost said overlaid
block, and communicate to said cavity of a lowest said underlying
block which communicates with said pathway passageway.
16. The interlocking block system of claim 6 additionally
comprising: a pathway communicating between all said overlaid
blocks and any portions of any said underlying blocks; and said
pathway formed between the sidewalls of all overlaid and underlying
blocks by portions of said pair of cavities of each overlaid block,
communicating with lower portions of cavities of underlying blocks;
whereby cementitious material may be poured into the pathway
communicating with said top surface of an uppermost said overlaid
block, and communicate to said cavity of a lowest said underlying
block which communicates with said pathway passageway.
17. The interlocking block system of claim 1 additionally
comprising: a recess formed in an upper surface of said central
potion of each said block; and a horizontal pathway formed in each
said block communicating between said open areas through said pair
of cavities and said recess, whereby said horizontal pathway
communicates through each said block engaged at distal edges with
an adjacent said block in a row of said blocks forming a layer.
18. The interlocking block system of claim 14 additionally
comprising: a recess formed in an upper surface of said central
potion of each said block; and a horizontal pathway formed in each
said block communicating between said open areas through said pair
of cavities and said recess, whereby said horizontal pathway
communicates through each said block engaged at distal edges with
an adjacent said block in a row of said blocks forming a layer.
19. A method of building a reinforced wall of individual "H" shaped
blocks having two sidewalls extending to engageable distal edges
and openings between said distal edges communicating with cavities
between a center section of said block and said two sidewalls
wherein said blocks are placed in coplanar layers of blocks with
reinforcing members running traverse through said layers,
comprising the steps of: engaging the engageable distal edges of
each said block forming a layer; upon encountering a reinforcing
member during positioning of a said block to be placed in a said
layer, communicating said member through one of said openings of
said block to be placed, and thereafter into said communicating
cavity; and subsequently, engaging said distal edges of said block
to be placed with said distal edges of an adjacent said block
already positioned in said layer.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to blocks which are
conventionally employed to build privacy and retaining walls. More
particularly, the device herein disclosed relates to a block system
which allows the user to employ only two types of block to build
any wall and optionally three types. The system employs a full
sized block having a novel "H" shape. An entire wall may be formed
of this single block.
[0003] The unique "H" shaped block and "C" shaped block allow the
user to build a wall with a high degree of sheer strength through
the provision of projecting pins which engage with overhead blocks
in the formed wall. Additional strength in the formed wall may be
provided through interweaving vertical metal reinforcing bars which
communicate through the levels of engaged blocks. When used in
combination with such reinforcing bars, the device and method
herein disclosed yields great utility by allowing the reinforcing
bars and blocks to be interfaced without the need to lift the heavy
blocks over the top of distal end of the metal bar as is
conventionally done. Walls with reinforcing bars can thus be built
quicker and with less exertion and injuries to the workers
building. Employing the embodiments of the blocks herein described
and disclosed, the endwalls of the blocks used are open and allow
the blocks to simply be angled around the reinforcing bar and
engaged with each other with formed pins which project above the
top surface of each block and engage with cavities in the bottom of
overriding blocks. Projecting endwall tongue and groove engagement
is also provided for an extremely strong engagement of all the
blocks forming any one wall. The resulting wall is built in less
time and provides resistance to earthquakes and other lateral
forces which might cause failure in walls lacking the structural
integrity provided by the interlocking system of pins and cavities
and allowance for easy use of reinforcing bar.
[0004] 2. Prior Art
[0005] The building of walls goes back to ancient times when rocks
were used. Modern wall building conventionally employs blocks to
build decorative and retaining and privacy walls. Conventional
techniques, especially where the wall is to retain soil from
subsidence or provide a building foundation, use blocks with closed
cavities, smooth endwalls, and generally planar upper and lower
surfaces. The blocks are stacked upon each other with each
subsequent layer of blocks overlapping the underlying seams between
individual blocks. Because of the smooth surfaces of the blocks,
they rely upon the mortar, grout or cement to hold them in
engagement to each other. To insure that this engagement is
permanent and to provide additional strength against lateral forces
and earthquake type forces, most conventional block walls employ
vertical steel rods and on many types of construction, horizontal
steel rods which communicate to adjacent blocks. The steel
reinforcement rods must be threaded through closed cavities of
conventional blocks used, and once all the blocks and steel are
properly placed, mortar, grout or similiar cement-like material is
then filled into the closed cavities. The cementitious material,
once dried, will lock the metal bars and the blocks in a fixed
engagement with each other.
[0006] As is well known, the requirement of placing blocks adjacent
to each other in proper spacing to form a layer and repeating the
process with each overhead layer supported by underlying layers is
tedious. Further, it requires a great expenditure in time and
energy on the part of workers, and because of the nuances of
engaging adjacent blocks and interwoven steel rods with sufficient
cement mortar or grout, block formed walls require a lot of worker
skill to complete successfully and aesthetically. This is
especially true when reinforcing bars are employed and interwoven
between lower brick layers and those above them. Not only must the
metal bars be properly placed and interwoven as the wall is built
upward, the blocks themselves must be lifted upward above the
distal high end of the vertical reinforcing bars, and once there,
they must be lowered with the reinforcing bar threaded into the
internal cavities of the block. With each block weighing between 28
to 36 pounds, this is a daunting and exhausting task for even the
most experienced block builder.
[0007] Further, typical conventional concrete blocks have smooth
side surfaces and generally planar top and bottom surfaces on which
the blocks engage underlying or overlying block layers in a wall.
Such construction provides no means to interlock overhead blocks to
underlying layers of blocks in the wall. Conventional concrete
blocks generally offer no endwall means of engagement to adjacent
blocks in a given layer either. Instead, conventional concrete
blocks are designed to be aligned in individual layers of adjacent
blocks with subsequent layers formed in the same fashion stacked on
top of each other. The grout or mortar must be properly mixed and
then expertly applied to each individual block surface that engages
an adjacent surface to insure that all blocks in all layers remain
engaged by the dried mortar. Of course the application of mortar to
the exterior of the individual blocks and through channels formed
in the wall only occurs once each block in the wall has been raised
over the distal end of the vertical metal reinforcing rods and then
held while they are slid down the reinforcing bar to their intended
place. Not only must the worker use energy to raise the block up
and over the metal bars, the worker then must use additional energy
to resist gravity's pull on the block while it is lowered to its
proper position. Dropped blocks can cause severe damage to already
mortared underlying layers as well as to the dropped block itself.
Once so lowered, the individual blocks must be coated with mortar
which is allowed to dry before the blocks of the different layers
are held in place by the dried cement or mortar or similar
cement-like material. If the mortar is improperly mixed or applied,
the resulting wall will eventually fail due to slippage of the
blocks. Consequently, the skill level for a journeyman block wall
mason using conventional blocks in a fashion that will yield a wall
with the intended strength and look is fairly high and beyond the
scope of most inexperienced workers, homeowners, and uneducated
workers in third world countries. While the lack of skill may not
dissuade such workers from building walls, the resulting
construction can easily be sub-standard and fail, resulting in
great property loss and worse yet, loss of life.
[0008] Still further, a common complaint with interlocking block
styles is that because they interlock, the wall as built is not
easily adjustable for length. Non-interlocking blocks in the hands
of a good mason may be laid apart and separated by mortar at
varying distances to either stretch or shrink the resulting wall.
However, interlocking blocks generally must interlock with adjacent
blocks above and below at very specific points and are not
adjustable.
[0009] As such, there exists a continuing unmet need for a block
system which will provide for easy building of high-strength walls
by both low-skilled and highly skilled workers. Such a device and
method should provide a strong wall with excellent lateral support
against slippage by adjoining, overhead, and underlying blocks.
Such a device and system should provide for engagement of metal
reinforcing rods vertically through all the layers of the block
wall and should eliminate the need to lift the heavy blocks and
then restrain them as they slide over the vertical elongated steel
reinforcing bars. Further, such a device and system should provide
a means to interlock adjacent blocks on the same level of the wall
to provide additional shear strength to the wall once build. Still
further, such a device and method should be simple and have as few
parts to the block building system as possible to allow for use by
unskilled, uneducated workers, and to minimize the number of types
of blocks that must be shipped to a building site. Finally, such a
device and method of building thereby provided should allow for
adjustment of the spacing of adjacent blocks on each layer during
construction by allowing for a locked engagement with adjustment
through horizontal translation of individual blocks while
continuing to provide overhead interlocking. This adjustment
provision the builder to shrink or stretch the length of the wall
by a few inches depending on how the blocks are engaged, yet still
provides a positive interlock of the distal ends and the interior
of the sidewalls of the blocks in the wall. This adjustability
along with the use of only one block style, if desired, allows for
the use of unskilled workers to build high strength and visually
pleasing walls even if they make errors in actual placement and
engagement to adjacent blocks and overhead and underlying
layers.
SUMMARY OF THE INVENTION
[0010] The device herein disclosed provides concrete blocks for
construction of walls using a single block design or two or more
block designs that provide for an especially easy method to
construct a sturdy wall. The device in all modes employs an "H"
shaped first block design which incorporates a number of
interlocking features that improve strength and stability of walls
and structures. The block also incorporates a double open-end
design which eliminates the endwalls required by conventional
rectangular blocks. This provision of open endwalls allows for
improved vertical metal reinforcing rod engagement between layers
of blocks forming the wall without the need to lift and slowly
lower the heavy blocks on the upright metal rods. Instead, the
blocks are simply angled to allow the open ends to slide around the
upright metal rods, thereby reducing the time and effort and number
of laborers required to build a wall of great strength. The block
may then be locked into place with cooperating projections and
receiving cavities of the other adjacent and lower interlocking
blocks with the re-bar in the proper location in the block
cavity.
[0011] Further, the double open-end design allows for improved
grout or mortar flow around reinforcing steel and block cavity
filling, thereby allowing a higher number of levels or layers of
the blocks to be operatively engaged with each other and
subsequently internally grouted from above through formed channels
for the mortar or grout to flow.
[0012] In all embodiments of the device, be it the single block
system or employing a second block for aesthetic purposes, the
tapered vertical interlocking pins and cooperative engagements for
the pins in adjacent overhead blocks allow for tolerances during
the building process which provide for longitudinal adjustment of
up to 1/8 inch per block. This provides a means adjustment of the
final length of the wall as-built and provides a remedy in case of
any errors in placement of a block in a layer forming the wall.
[0013] Still further, the H-Block design provides a "re-bar chase"
or bond beam recess which is pressed into the middle web of the
block. The recess provides for additional easy reinforcement of the
wall by allowing the placement of horizontal reinforcing metal rods
which run through adjacent blocks on a single layer. Using the
unique open-ended blocks and included means for adjustment of
placement and interlocking components of all the blocks,
experimentation has shown a building rate of up to ten times faster
for laying the H-block than a conventional mortared block due to
the elimination of the need to place the block over the reinforcing
steel. Additionally, the workers can be of minimal skill and
education since the blocks interlock with each other, and in the
simplest mode of the device there is only one block style used.
[0014] Because the blocks are manufactured of conventional
materials in conventional sizes, manufacturing of the blocks is
accomplished in the same manner as for conventional blocks and uses
the same types of machines. This allows the device and method to be
easily and inexpensively integrated into current manufacturing
plants.
[0015] With respect to the above description, before explaining at
least one preferred embodiment of the herein disclosed invention in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and to the
arrangement of the components in the following description or
illustrated in the drawings. The invention herein described is
capable of other embodiments and of being practiced and carried out
in various ways which will be obvious to those skilled in the art.
Also, it is to be understood that the phraseology and terminology
employed herein are for the purpose of description and should not
be regarded as limiting.
[0016] As such, those skilled in the art will appreciate that the
conception upon which this disclosure is based may readily be
utilized as a basis for designing of other structures, methods and
systems for carrying out the several purposes of the present
disclosed device. It is important, therefore, that the claims be
regarded as including such equivalent construction and methodology
insofar as they do not depart from the spirit and scope of the
present invention.
[0017] It is an object of this invention to provide a block
building system that requires only one type of block thereby
minimizing the number and type of blocks that must be shipped and
assembled into a wall.
[0018] It is another object of this invention to provide such a
block building system that provides interlocking engagements to
blocks on adjacent sides in a layer of blocks and with blocks in
layers above and below each block in the wall.
[0019] It is a further objection of this invention to provide such
a block building system that allows for the use of vertical metal
reinforcing bars and eliminates the need to raise the blocks to
high levels and hold them against gravity while they descend, when
incorporating such steel reinforcing bars between layers of a
wall.
[0020] It is a further object of this invention to provide blocks
that may easily be assembled into a wall with exceptional shear
strength by unskilled workers.
[0021] Yet an additional object of this invention is the provision
of an interlocking block system for wall construction that provides
for adjustment of the spacing between blocks on any one layer with
adjacent blocks to provide means of adjustment of the length of the
spacing and ultimate all length.
[0022] Further objects of the invention will be brought out in the
following part of the specification, wherein detailed description
is for the purpose of fully disclosing the invention without
placing limitations thereon.
BRIEF DESCRIPTION OF DRAWING FIGURES
[0023] FIG. 1 depicts a perspective view of the "H" shaped
interlocking block of the disclosed device and method.
[0024] FIG. 2 depicts a wall being built showing the open ended
interlocking blocks being angled into place by sliding the open
ends past upright reinforcing bars.
[0025] FIG. 3 is a top plan view of the "H" shaped block of FIG. 1
showing the interlocking pins above the top surface and
interlocking sidewall distal edges adapted to engage adjacent
blocks.
[0026] FIG. 4 depicts an end view of the block of FIG. 1 showing
the distal edges of the sidewalls and open end.
[0027] FIG. 5 depicts a typical stacking of layers with the blocks
engaged to adjacent blocks in any layer and blocks situated in
adjacent overhead layers and the gap for translation
adjustment.
[0028] FIG. 6 depicts a wall formed of the blocks herein and the
channels formed inside the wall for mortar flow through multiple
formed layers of engaged blocks.
[0029] FIG. 7 shows an optional half-block that may be employed for
finished ends on walls built with the first block and typical pins
for both the block of FIG. 1 and the half block.
[0030] FIG. 8 depicts a top perspective view of another optional
full block that may be employed as an end block, or a corner block
for a perpendicular engaging wall, or a stretcher for use in
combination with the first block of FIG. 1. Also shown is an
alternative means to engage distal ends which is tapered.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE
INVENTION
[0031] As shown in FIGS. 1-8, the device employs a one block
building system providing for building of a wall structure formed
of single interlocking block style. The device 10 provides great
utility in the building of walls with interlocking blocks 12 as
shown in FIGS. 2 and 6, using a generally "H" shaped primary blocks
12 which can be employed as the sole block used in building a wall
14. The block 12 is formed in this shape by a pair of parallel
sidewalls 30 extending from a middle portion 31. The primary block
12 will allow for the building of straight walls or walls with
corners engaged to traverse walls 15 where the primary block 12
would be employed as a corner block anchoring the walls
perpendicular to each other.
[0032] When employed as a one block method or system, the primary
block 12, on a retaining wall can have its opposing open ends 16,
at both termination points at the sides of the wall, filled with
mortar or concrete or simply left open and filled with adjacent
soil if the wall 14 is a retaining wall. Or when employed as a one
block system to build a building, the primary block 12 will
function as a corner block 18 to provide interlocking corners to
the walls on every other layer of blocks forming the building
walls. As noted in this specification, half blocks 19 or specially
configured secondary blocks 21 might be employed as an option to
yield more aesthetically pleasing results on a straight wall such
as shown in FIG. 6; however, because of the interlocking
capabilities of the primary block 12, when used for a retaining or
other straight wall, the half blocks 19 might also be left out of
the wall and any half gaps between layers of blocks 12 covered with
adjoining soil or filled with concrete for aesthetic purposes while
still yielding a perfectly sound and strong straight wall.
[0033] The primary block 12 incorporates a number of means for
interlocking with adjacent primary blocks 12 or secondary blocks if
employed, which improve both the strength and stability of walls 14
and structures formed of one wall or engaged to adjoining walls 14.
At both ends of the primary block 12 are open ends 16 exposing
first and second internal cavities 20. As depicted in FIG. 2 and
FIG. 6, two open ends 16 communicating with internal cavities 20 on
the primary block 12, provide for improved interlayer communication
of reinforcing bar 22. The open ends between the distal ends of the
block sidewalls 30 also provide for easy placement of individual
primary blocks 12, engaged with reinforcing bar 22 through multiple
layers 26, without the need to lift the heavy primary blocks 12
over the elevated distal end 24 of the reinforcing bar 22 and
subsequently supporting the heavy block while it is lowered into
position as is done with conventional blocks. Because the open ends
16 at the distal ends of the sidewalls 30 provide means to engage
the blocks 12 with reinforcing bar 22 communicating therethrough,
without any lifting or lowering, there is a significant reduction
in the amount of time and user effort required. Instead, walls 14
having reinforcing bars 22 vertically interposed between layers 26
of overlying and underlying primary blocks 12, may be quickly
constructed with much less effort since the primary blocks 12 may
be angled into place between fixed reinforcing bars 22 and then
engaged with adjacent primary blocks 12 as depicted in FIG. 2.
[0034] Once positioned on a layer 26 in the wall 14, the primary
block 12 or the second block when optionally employed may then be
secured in an interlocking engagement with blocks in adjacent
underlying layers 26, and with primary blocks 12 in adjacent
positions on the same layer 26, using one or more means for
interlocked engagement.
[0035] A first means for interlocked engagement is provided for
interlocking all of the primary blocks 12 on an individual layer 26
with adjacent coplanar primary blocks 12. This interlocked
engagement is provided by interlocking of the pairs of distal ends
28 of the sidewalls 30 of adjacently located primary blocks 12.
Means for interlocking the distal ends 28 with the distal ends 28
of adjacently located coplanar primary blocks 12, in the current
favored mode of the device 10, employ a projection 32 adapted for
engagement in a recess 34 on the matching distal end the adjacent
primary blocks 12. This tongue and groove style engagement shown on
distal ends in FIGS. 1 and 3 and 7 and 8, provides great shear
strength to the engaged distal ends and to the constructed wall 14,
and in many cases the interlocking blocks 12 with this and vertical
interlocking means will not need reinforcing bar 22 to support the
load intended. Of course those skilled in the art will realize that
other means for interlocking the distal ends 28 of adjacent blocks
12 might be employed and all such means of engagement as would
occur to those skilled in the art are anticipated. However, because
of the unique ability of the primary blocks 12 to be angled into
engagement between reinforcing bars 22 and then the projections 32
slid into engagement with recess 34, and to maintain that
engagement even if the blocks are slid apart or together in an
adjustment, this projection 32 and recess 34 is favored. A
particularly preferred mode of the projections 32 is shown in FIG.
8 wherein the projections 32 are tapered which tend to help the
block self-align when being angled in place around reinforcing bar.
The taper makes it much easier to angle the block 12 while
concurrently engaging the two pair of respective distal ends of
adjacently laid blocks 12 in a layer 26.
[0036] Also in the preferred mode of the device 10 all of the
primary blocks 12 are provided a means for interlocking primary
blocks 12 on one layer 26 to adjacent primary blocks 12 in layers
26 above and below any primary block 12 in any layer 26. The only
layer 26 not engaged to primary blocks 12 below it would be the
first or lowest layer 26 in the wall 14, since there are no
interlocking pins 36 below it on other blocks 12. However, if the
wall 14 is constructed on a foundation of cement or other planar
foundation, the pins 36 can be formed in that foundation top
surface, providing an excellent engagement of the bottom layer to
its underlying foundation.
[0037] In the current favored mode of the device 10 the means for
interlocking primary blocks 12 on a lower layer 26 with any
adjacent primary block on an overhead layer 26 is provided by
interlocking pins 36 which project above the substantially planar
top surface 38 of the primary blocks 12. As shown in FIG. 5, the
pins 36 are adapted for cooperative engagements between internal
shoulders 40 engaged to the planar inner surface 41 of each
sidewall 30. The shoulders have side edges 35 which are evenly
spaced a distance from the center of the block 12.
[0038] A first side surface 39 of the pins 36 adjacent to the top
surface 38 of the block 12 substantially coplanar with the inner
surface 41 of the sidewall 30 from which the pin 36 extends above
the top surface. It is thus adapted for a frictional engagement on
the inner surface 41 on an overhead coplanar primary blocks 12
located with distal ends substantially centered on the underlying
block 12.
[0039] A second side surface 44 traverse to the first side surface
39 of the pins 36 is adapted for engagement against, or spaced
from, the side edges 35 of the shoulders 40 of the overhead primary
blocks 12. This provides two means of engagement of the lower
primary blocks 12 with those above.
[0040] In a particularly preferred mode of the device 10, the
distal end of the pins 36 would taper from their center axis to
their side edges to provide a tapered point 45 to provide a means
for self alignment of primary blocks 12 on higher layers 26 with
those on lower layers when laid thereon. Of course the blocks 12
structurally will be the same with or without the points 45 so they
could be made without them and such is anticipated.
[0041] A second side surface 44 of the pins is adapted for
engagement on, or space by a gap 43 from, a respective side edge 35
of the shoulders 40. The side edges 40 of the shoulders are spaced
a distance substantially equidistant from the center of the block
12. This distance "D" is slightly more than the distance from the
opposing side surfaces 44 of two blocks 12 engaged fully at their
distal ends 28 providing a slight gap 43 between one or both of the
side surfaces 44 and the side edges 35 when the distal ends are
fully engaged. This gap 43 provides a means for allowance of the
spacing between adjacent blocks 12 from each other from a maximum
spacing where there is no gap 43 to a minimum spacing where the gap
43 would be its greatest from one or both side surfaces and side
edges 35. Adjustment of the spacing, and therefore the wall length,
may be achieved by changing the spacing of the sliding engagement
of the distal ends 28 of the blocks 12 during the layering building
process. Currently the maximum gap 43 is about 1/8 of an inch
providing up to that much adjustment of block spacing at each
engagement of distal ends 28. However, other maximums might be
employed and are anticipated. Of course the distal ends 28 of each
adjacent block 12 remain fully engaged with the projection 32 and
recess 34 since they will slide in their engagement to allow the
adjustment. With such a longitudinal adjustment of up to 1/8 inch
in the current preferred mode of the device 10, this would allow
for an inch adjustment for every eight blocks 12 engaged in a layer
of a wall 14 and thus an adjustment of the length of the formed
wall 14 even through all the blocks 12 in the wall 12 would still
remain interlocked. With the first side surface 39 of all pins 36
engaged against the inner surface 41 of all overhead blocks 12,
there is still great shear strength imparted to the formed wall 14
even with the gap 43 on one or both engagements of the second side
surface 41 with the shoulders 40. Further, if mortar is employed to
fill the wall, the gaps 43 will later be filled locking the second
side surface 44 in its position against, or spaced from, the
shoulder 40.
[0042] As such, in the preferred mode of the device 10 the primary
blocks have a plurality of the pins 36 projecting above their
respective top surfaces 38 adapted for engagement against the
inside surfaces 41 of above mounted blocks 12 and a spaced
engagement both shoulders 40 providing means for lateral
translation of the blocks 12 in their engagement at their distal
ends 24 to adjust wall length and fitment of the blocks 12 with
each other. Using the slidable projections 32 engaged into recesses
34, all of the distal ends 28 of the sidewalls 30 are also engaged
and will also allow for a translation back and forth in that
engagement.
[0043] Additionally provided another especially preferred mode of
the device 10 may be a means for communicating reinforcing bar 22
vertically through adjacent horizontal layers 26 formed of the
primary blocks 12. The current preferred mode of providing the
means for communicating reinforcing bar 22 through the layers is
provided by adapting the internal cavities 20 of the individual
primary blocks 12 for alignment with those of other layers. The
internal cavity of lower layered blocks 12 aligns with a portions
of the internal cavities 20 of above situated blocks 12 no matter
what layer 26 they are located upon. This adaption for alignment
provides a path 46 for reinforcing bar 22 through the layers 26,
and also forms a channel 48 communicating between blocks 12 on
adjacent layers 26 through which mortar or other cementitious
material deposited into an upper layer 26 of the wall 14 will
communicate into lower layers 26.
[0044] Still further, in an especially preferred mode of the device
10 using the primary blocks 12, there is provided a means to
horizontally route reinforcing bar 22 through a "re-bar chase" or
bond beam recess 50 which is formed into the middle portion 31 of
the primary block 12 to form a horizontal channel 52 communicating
through all engaged adjacent blocks 12 in the layers 26 of engaged
primary blocks 12. Using this channel 52 the wall 14 formed may be
reinforced with reinforcing bar 22 horizontally for greater
strength.
[0045] With respect to the above description, before explaining at
least one preferred embodiment of the herein disclosed invention in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and to the
arrangement of the components in the following description or
illustrated in the drawings. The invention herein described is
capable of other embodiments and of being practiced and carried out
in various ways which will be obvious to those skilled in the art.
Also, it is to be understood that the phraseology and terminology
employed herein are for the purpose of description and should not
be regarded as limiting.
[0046] While all of the fundamental characteristics and features of
the open ended blocks with interlocking edges have been shown and
described herein with reference to particular embodiments thereof,
a latitude of modification, various changes and substitutions are
intended in the foregoing disclosure, and it will be apparent that
in some instances some features of the invention may be employed
without a corresponding use of other features without departing
from the scope of the invention as set forth. It should also be
understood that various substitutions, modifications, and
variations may be made by those skilled in the art without
departing from the spirit or scope of the invention. Consequently,
all such modifications and variations and substitutions are
included within the scope of the invention as defined by the
following claims.
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