U.S. patent application number 11/673737 was filed with the patent office on 2007-06-14 for web offset lug dry-stack system.
This patent application is currently assigned to FSN, LLC. Invention is credited to Alan C. Ferguson.
Application Number | 20070130854 11/673737 |
Document ID | / |
Family ID | 34984668 |
Filed Date | 2007-06-14 |
United States Patent
Application |
20070130854 |
Kind Code |
A1 |
Ferguson; Alan C. |
June 14, 2007 |
WEB OFFSET LUG DRY-STACK SYSTEM
Abstract
Generally, the invention is a dry stack building block for
constructing a masonry wall. The dry stack unit has a front section
having an outer surface, an inner surface, a bottom surface, and a
top surface. The dry stack unit also has a rear section
substantially parallel to the front section having an outer
surface, an inner surface, a bottom surface, and a top surface. Two
or more webs coupling the inner surface of the front section to the
inner surface of the rear section have a top surface and a bottom
surface. Two or more pairs of lugs may extend above the top surface
of the front section and the top surface of the rear section. Each
pair of lugs may have a first lug offset from a second lug in an
axis perpendicular to the inner surfaces of the front section and
the back section.
Inventors: |
Ferguson; Alan C.; (Dacula,
GA) |
Correspondence
Address: |
BOURQUE & ASSOCIATES;INTELLECTUAL PROPERTY ATTORNEYS, P.A.
835 HANOVER STREET
SUITE 301
MANCHESTER
NH
03104
US
|
Assignee: |
FSN, LLC
Manchester
NH
|
Family ID: |
34984668 |
Appl. No.: |
11/673737 |
Filed: |
February 12, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11255565 |
Oct 21, 2005 |
7174687 |
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11673737 |
Feb 12, 2007 |
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11007968 |
Dec 9, 2004 |
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11255565 |
Oct 21, 2005 |
|
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60529457 |
Dec 12, 2003 |
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Current U.S.
Class: |
52/270 |
Current CPC
Class: |
E04B 2/54 20130101; E04B
2002/023 20130101; E04B 2002/0215 20130101; E04B 2002/8676
20130101; E04B 2002/867 20130101; E04B 2/52 20130101; E04B 2/8629
20130101 |
Class at
Publication: |
052/270 |
International
Class: |
E04B 7/00 20060101
E04B007/00; E04B 1/00 20060101 E04B001/00 |
Claims
1. A dry stack building block for constructing a masonry wall
comprising: a front section having an outer surface, an inner
surface, a bottom surface, and a top surface; a rear section,
substantially parallel to the front section and having an outer
surface, an inner surface, a bottom surface, and a top surface; two
or more webs coupling the inner surface of the front section to the
inner surface of the rear section, each of the two or more webs
having a top surface and a bottom surface; and two or more pairs of
lugs, each pair of lugs disposed proximate one of the two or more
webs and extending above the top surface of the front section and
the top surface of the rear section, extending an entire length of
the front section and the rear section, and wherein each pair of
lugs has a first lug offset from a second lug, said offset disposed
about an axis perpendicular to the inner surfaces of the front
section and the back section wherein the two or more pairs of lugs
are positioned to receive a second duplicate dry stack block
rotated 180 degrees and centered directly on top the dry stack
building block.
2. The dry stack building block of claim 1, wherein one pair of the
two or more pairs of lugs are positioned to receive a second
duplicate dry stack block staged halfway off-center and a second
pair of the two or more lugs are positioned to receive a third
duplicate dry stack block staged halfway off-center in a direction
opposite and adjacent to the second stack block.
3. The dry stack building block of claim 1, wherein the top
surfaces of the front section and rear section are adapted to
receive a bottom surface of a front section and a bottom surface of
a rear section of another duplicate dry stack building block.
4. The dry stack building block of claim 1, wherein the outer
surface of the front section and the outer surface of the rear
section have a chamfered edge.
5. The dry stack building block of claim 1, wherein a first lug of
each pair of the two or more pairs of lugs has a chamfered edge
adjacent to the front section and the second lug of each pair of
the two or more pairs has a beveled edge adjacent to the rear
section.
6. The dry stack building block of claim 1, wherein the two or more
webs are substantially perpendicular to the front section and the
rear section.
7. The dry stack building block of claim 6, wherein the two or more
webs has one lug of a first pair of the two or more pairs of lugs
adjacent to the inner surface of the front section and a first side
surface of a first web of the two or more webs and a second lug of
the first pair adjacent to the inner surface of the rear section
and a second side surface opposite the first side surface of the
first web of the two or more webs and one lug of a second pair of
the two or more pairs of lugs adjacent to the inner surface of the
front section and a first side surface of a second web of the two
or more webs and a second lug of the second pair adjacent to the
inner surface of the rear section and a second side surface
opposite the first side surface of the second web of the two or
more webs.
8. The dry stack building block of claim 1, wherein the first angle
produced by a first web of the two or more webs and the front
section plus a second angle produced by a second web of the two or
more webs and the front section is substantially equal to 180
degrees.
9. The dry stack building block of claim 8, wherein each of the two
or more webs has one lug of a pair of the two or more pairs of lugs
extending from the top surface of the web and adjacent to the front
section and a second lug of the pair extending from the top surface
of the web and adjacent to the rear section.
10. The dry stack building block of claim 1, wherein the two or
more webs have a knock-out portion for providing a bond beam.
11. A dry stack building block system for constructing a masonry
wall comprising a plurality of stretcher blocks, each stretcher
block comprising: a front section having an outer surface, an inner
surface, a bottom surface, and a top surface; a rear section
substantially parallel to the front section having an outer
surface, an inner surface, a bottom surface, and a top surface; two
or more webs coupling the inner surface of the front section to the
inner surface of the rear section; and two or more pairs of lugs
disposed directly on top of one of the two or more webs and
extending above the top surface of the front section and the top
surface of the rear section and each pair of lugs for each web of
the two or more webs has a first lug offset from a second lug in an
axis running perpendicular to the inner surfaces of the front
section and the back section wherein the two or more pairs of lugs
are positioned to fit within a second duplicate dry stack block
rotated 180 degrees and centered directly on top the dry stack
building block.
12. The dry stack building block system of claim 11, wherein one
pair of the two or more pairs of lugs are positioned to receive one
of a second duplicate stretcher block and a third duplicate
stretcher block staged halfway off-center.
13. The dry stack building block system of claim 11, wherein the
top surfaces of the front section and rear section are adapted to
receive a bottom surface of a front section and a bottom surface of
a rear section of one of a duplicate stretcher block.
14. The dry stack building block system of claim 11, wherein the
outer surface of the front section and the outer surface of the
rear section of the stretcher block have a chamfered edge.
15. The dry stack building block system of claim 11, wherein a
first lug of each pair of the two or more pairs of lugs has a
chamfered edge adjacent to the front section and the second lug of
each pair of the two or more pairs has a beveled edge adjacent to
the rear section.
16. The dry stack building block system of claim 11, wherein the
two or more webs of the stretcher block are substantially
perpendicular to the front section and the rear section of the
stretcher block.
17. The dry stack building block system of claim 16, wherein each
of the two or more webs of the stretcher block has one lug of a
pair of the two or more pairs of lugs adjacent to the inner surface
of the front section and a first side surface of the web and a
second lug of the pair adjacent to the inner surface of the rear
section and a second side surface opposite the first side surface
of the web.
18. The dry stack building block system of claim 11, wherein the
first angle produced by a first web of the two or more webs and the
front section of the stretcher block plus a second angle produced
by a second web of the two or more webs and the front section of
the stretcher block substantially equal to 180 degrees.
19. The dry stack building block system of claim 18, wherein each
of the two or more webs of the stretcher block has one lug of a
pair of the two or more pairs of lugs extending from the top
surface of the web and adjacent to the front section and a second
lug of the pair extending from the top surface of the web and
adjacent to the rear section.
20. A dry stack building block for constructing a masonry wall
without mortar joints comprising: a front section having an outer
surface, an inner surface, a bottom surface, and a top surface; a
rear section substantially parallel to the front section having an
outer surface, an inner surface, a bottom surface, and a top
surface; means for coupling the inner surface of the front section
to the inner surface of the rear section and having a top surface
and a bottom surface wherein the means for coupling are aligned on
top of each other as successive rows of block are stacked; and
means for providing alignment of stacked blocks wherein the means
for providing alignment extends above the top surface of the front
section and the top surface of the rear section and extends an
entire length of the front section and the rear section, each pair
of protrusions for each means of coupling has a first protrusion
offset from a second protrusion in an axis within a plane centered
about and parallel with the means for coupling and perpendicular to
the inner surfaces of the front section and the back section, is
immediately adjacent the means for coupling, and enter within a
cell produced by a front section, a rear section and a means for
coupling of a successive row of staged stacked blocks.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional application of U.S.
application Ser. No. 11/255,565 filed Oct. 21, 2005, incorporated
by reference herein and for which benefit of the priority date is
hereby claimed. Application Ser. No. 11/255,565 is a continuation
of Ser. No. 11/007,968 filed Dec. 9, 2004, which claims priority
from U.S. provisional patent application Ser. No. 60/529,457, filed
Dec. 12, 2003, by Alan Corbett Ferguson, incorporated by reference
herein and for which benefit of the priority date is hereby
claimed.
TECHNICAL FIELD
[0002] The present invention relates to dry-stack concrete masonry
systems for building structural load bearing and non-load bearing
walls and, more particularly, two distinct concrete masonry units
with a web offset lug design that provides for both stack bonding
and running bond construction with unobstructed vertical cell
alignment to facilitate both solid and partial concrete grouting
(for structural strength) with and without steel reinforcement.
BACKGROUND INFORMATION
[0003] An advantage of dry stack masonry systems is that the labor
component of installation can be dramatically reduced. Some studies
have shown that dry stack masonry systems are up to ten times
faster to install than conventional joint mortared masonry systems.
Because these systems do not use bonding mortar to provide joint
support, it may be necessary to use other means of developing wall
strength.
[0004] One technique to develop wall strength is to pour wet
concrete or grout into the openings of the block to form vertical
posts. The wet concrete is poured into the open cells of the
concrete block. Various building codes may require dry-stacked
concrete block cells to be filled differently in order to provide
specified structural integrity. Some applications may require all
the cells to be filled with concrete. Other applications may
require the concrete to be poured into distinct vertical columns
and only in certain cells or cores of the block. These applications
may require cells, for example, to be filled generally at four foot
on center increments and/or at wall corners and jambs of windows
and doors or various load points. A general overview of the use of
current dry stack methods in masonry wall construction can be found
in National Concrete Masonry Association's (NCMA) technical
publication TEK 14-22 "Design and Construction of Dry-Stack Masonry
Walls."
[0005] The vertical posts are typically reinforced with
reinforcement members, for example, steel rebar. The problem with
many dry stack block systems is that when stacked, the cells or
core holes of the block are not completely aligned. The cells
between successive layers of block may vary in size as shown in
FIGS. 1A and 1B. FIGS. 1A and 1B show a stack of a conventional dry
block system 100. The middle row 102 provides a narrow passage 104
relative to the top row 106 and bottom row 108. When concrete is
poured in the cells the variation in cell dimensions may hinder or
prevent reinforcement members from being inserted in the cores to
form the vertical posts. In addition, the variation in cell
dimensions may make it difficult to fill the voids within the cell.
Many conventional dry stack block systems may provide little or no
damming capacity when filling the cells of a dry stack block wall
structure.
[0006] The current dry stack wall systems used in building
construction for load bearing and non-load bearing walls that
incorporate raised lugs for alignment and interlocking do not
provide adequate or uniform core orientation, as previously
discussed. Additional descriptions of prior art raised lug systems
are disclosed in U.S. Pat. No. 3,968,615 to Ivany, U.S. Pat. No.
4,182,089 to Cook, and U.S. Pat. No. 4,640,071 to Haener.
[0007] When stacked in a running bond, a core block resting on top
of two halves of a lower adjacent block, the lack of uniform
orientation of prior art systems fail to provide a uniform and
well-aligned core for forming concrete posts. The prior art
dry-stack block systems require lugs that project above the top
surface of the block. These lugs tend to limit where blocks can be
stacked in relation to one another. In addition, the prior art
alignment of lugs prevents the stacking of blocks in a single stack
bonded configuration (one block resting completely on top of a
lower adjacent block).
SUMMARY
[0008] In one aspect the invention features a dry stack building
block for constructing a masonry wall. The block may have a front
section having an outer surface, an inner surface, a bottom
surface, and a top surface. The block may also have a rear section
substantially parallel to the front section having an outer
surface, an inner surface, a bottom surface, and a top surface. Two
or more webs may couple the inner surface of the front section to
the inner surface of the rear section and having a top surface and
a bottom surface. Two or more pairs of lugs may extend above the
top surface of the front section and the top surface of the rear
section. Each pair of lugs may have a first lug offset from a
second lug in an axis running parallel to the top surfaces of the
front section and the back section and perpendicular to the inner
surfaces of the front section and the back section.
[0009] Embodiments may include one or more of the following. One
pair of the two or more pairs of lugs may be positioned to receive
a second duplicate dry stack block staged halfway off-center and a
second pair of the two or more lugs may be positioned to receive a
third duplicate dry stack block staged halfway off-center in a
direction opposite and adjacent to the second stack block. The top
surfaces of the front section and rear section may be adapted to
receive a bottom surface of a front section and a bottom surface of
a rear section of another duplicate dry stack building block. The
outer surface of the front section and the outer surface of the
rear section may have a chamfered edge. A first lug of each pair of
the two or more pairs of lugs may have a chamfered edge adjacent to
the front section and the second lug of each pair of the two or
more pairs has a beveled edge adjacent to the rear section. The two
or more webs may be substantially perpendicular to the front
section and the rear section. Each of the two or more webs may have
one lug of a pair of the two or more pairs of lugs adjacent to the
inner surface of the front section and a first side surface of the
web and a second lug of the pair adjacent to the inner surface of
the rear section and a second side surface opposite the first side
surface of the web. A first angle produced by a first web of the
two or more webs and the front section plus a second angle produced
by a second web of the two or more webs and the front section may
be substantially equal to 180 degrees. Each of the two or more webs
may have one lug of a pair of the two or more pairs of lugs
extending from the top surface of the web and adjacent to the front
section and a second lug of the pair extending from the top surface
of the web and adjacent to the rear section. The two or more webs
may have a knock-out portion for providing a bond beam.
[0010] In another aspect the invention may feature a corner block
for constructing a corner wall portion. The corner block may have a
front section having an outer surface, an inner surface, a bottom
surface, and a top surface. The corner block may also have a rear
section substantially parallel to the front section having an outer
surface, an inner surface, a bottom surface, and a top surface. A
side section may be coupled and substantially perpendicular to the
front section and the back section. The side section may have an
outer surface contacting the outer surfaces of the front section
and rear section, a bottom surface, and a top surface. The corner
block may have one or more webs coupling the inner surface of the
front section to the inner surface of the rear section and spaced
to receive the one or more pairs of lugs.
[0011] Embodiments of the invention may have one or more of the
following advantages. The invention may provide an improved
dry-stack concrete masonry block for constructing masonry load,
bearing and non-load bearing wall assemblies. The invention may
allow for improved core alignment from the bottom to the top of
wall construction. The invention may also make partial filling of
dry-stack block cells faster, easier, and stronger. The invention
may also make structural reinforcement of wall assembly easier and
faster in conjunction with concrete or without concrete (i.e. post
tensioned). The invention may also allow the installer to construct
in both running bonded and stack bonded orientations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] These and other features and advantages of the present
invention will be better understood by reading the following
detailed description, taken together with the drawings wherein:
[0013] FIG. 1A is a top plane view and FIG. 1B is a front cross
sectional side view of a prior art conventional dry stack block
assembled into a linear wall structure;
[0014] FIG. 2 is a perspective view of the present invention
comprising two dry-stack units, a stretcher unit and a corner unit
shown here assembled into a wall structure turning a 90 degree
corner;
[0015] FIG. 3 is a perspective view of present invention comprising
the two dry-stack units, the stretcher unit and the corner unit
shown here assembled into a linear wall structure;
[0016] FIG. 4A is a top plane view and FIG. 4B is a side profile
view of the stretcher unit according to an exemplary embodiment of
the invention with webs at non-right angles.
[0017] FIG. 5A is a top plane view and FIG. 5B is a side profile
view of the stretcher unit according to an exemplary embodiment of
the invention with webs at right angles.
[0018] FIG. 6A is a top plane view; FIG. 6B is a cross sectional
view; FIG. 6C is a front profile view; and FIG. 6d is a side
profile view of the stretcher unit according to an exemplary
embodiment of the invention with beveled lug profiles.
[0019] FIG. 7A is a top plane view; FIG. 7B is a front profile
view; and FIG. 7C is a side profile view of the corner unit
according to an exemplary embodiment of the invention.
[0020] FIG. 8A is a top plane view and FIG. 8B is a front cross
sectional side view of the stretcher unit assembled into a linear
wall structure.
[0021] FIG. 9 is a perspective view of the stretcher units stacked
according to an exemplary stack-bonding embodiment.
[0022] For purposes of clarity and brevity, like elements and
components will bear the same designations and numbering throughout
the FIGURES.
DETAILED DESCRIPTION
[0023] A corner wall structure 200 may use a stretcher unit 202 and
a corner unit 204 to construct the corner and straight portions of
a wall, as shown in FIG. 2. The stretcher units 202 have lugs 206
that extend above the top of the stretcher unit 202. The next
course of stretcher units is placed on top of the previous layer of
stretcher units. The lugs 206 of the previous layer of stretcher
units extend into the cells of the next course of stretcher units.
The lugs provide face shell alignment, lateral strength, and lock
together successive layers of units.
[0024] The stretcher units 202 have a front section and a rear
section. One or more webs or ribs couple the front section to the
rear section. The one or more webs may extend just below the top
surface of the stretcher unit 202 or may extend all the way to the
top surface of the stretcher unit 202. The stretcher units 202 also
have lugs that extend above the top surface of the stretcher unit
202. The stretcher unit 202 and other exemplary embodiments of the
stretcher unit 202 will be described in greater detail later
herein. The corner units 204 may also have a front section, rear
section, and one or more webs coupling the front section and rear
section. The corner unit also has a side section. The side section
provides a ninety-degree corner in the wall. The corner unit 204
provides a uniform surface at the corner of the wall. The corner
units 204 are staggered with each successive row. The corner unit
204 and other exemplary embodiments of the stretcher unit 202 will
be described in greater detail later herein.
[0025] The corner unit 204 may not have lugs extending from the
top. The corner unit may be used in a straight wall portion, as
shown in FIG. 3. The spacing and alignment of lugs, as will be
discussed later herein, allows the corner section to be placed
within a straight portion of the wall. The lugs of the lower
stretcher units 202 extend into the cells of the corner unit 204
without interfering with the side section or the webs of the corner
unit.
[0026] FIG. 4A is a top plane view and FIG. 4B is a side profile
view of a stretcher unit 400 according to an exemplary embodiment
of the invention with webs at non-right angles. The stretcher unit
400 may have a height of eight inches and a length of sixteen
inches. The stretcher unit 400 has a front section 402 and a rear
section 404. The front section 402 and the rear section 404 may
have a thickness of one and quarter (+/-) inches. One or more webs
406 couple the front section 402 to the rear section 404. The webs
406 may have a thickness of one and a half inches (+/-). The webs
406, according to this embodiment, are symmetrically angled between
the front section 402 and the rear section 404. Each web 406 has a
pair of lugs 408 extending from the top surface of the web. The
lugs 408 may extend above the top surface by 3/8.sup.th (+/-) of an
inch. The lugs may have a width and thickness of one inch (+/-).
The angled webs 406 allow the stretcher units to be stacked in a
staggered fashion without the lugs interfering with the web of a
successive layer of stretcher units. The web of the successive
layer of stretcher units straddles each pair of lugs 408. The
stretcher unit is supported in the lateral direction by a lug
positioned between the inner surface of the front or rear section
and the web.
[0027] The exemplary embodiments shown in FIGS. 4A and 4B may also
include round lugs. The lugs have a round top portion, which aids
in the stacking of successive stretcher units. The weight of
successive stretcher units pushing down centers the unit into the
correct resting position. The rounded lugs help to prevent
successive stretcher units becoming stuck or partially resting on
the lug of lower stretcher units. The exemplary embodiments shown
in FIG. 4B may also include a knock-out portion 410 for producing a
bonding-beam portion in the constructed wall. The knock-out portion
410 may extend down three inches (+/-) from the top surface. The
knock-out portion 410 may have a three quarter inch slot to allow
for placing reinforcement members or removing the knock-out portion
410. Bonding-beams are horizontal reinforcements in the wall that
add strength between the vertical columns of the constructed wall.
A row of stretcher units in a wall of individual or successive rows
may be designated for a bonding-beam. During construction the
knock-out portion 410 may be removed to allow reinforcement members
and/or poured concrete to fill the cells of a row of stretcher
units. The knock-out portion 410 may be molded into the stretcher
unit between the lugs 408 of the web 406.
[0028] The exemplary embodiments shown in FIGS. 4A and 4B may also
include chamfered edges on the sides for the front section and the
rear section. The chamfer allows the adjacent stretcher unit to fit
snuggly against the neighboring stretcher unit. The chamfers of
neighboring stretcher units overlap providing additional strength
and preventing leaking of concrete from the cell columns during
pouring. The chamfers may have a 3/8.sup.th (+/-) inch inset. The
exemplary embodiments shown in FIGS. 4A and 4B may also include
beveled edges on the outer surface of the front section and the
rear section. The beveled edges of the stretcher unit give the wall
a more traditional block construction look. The beveled edge
outlines the profile of the block without the need for grouted
joints. The edge is not limited to a bevel. The edge may have a
chamfer or other profile to outline the block face.
[0029] An exemplary embodiment of the invention with webs at right
angles is shown in FIG. 5A and FIG. 5B. The stretcher unit 500 has
a front section 502 and a rear section 504. One or more webs 506
couple the front section 502 to the rear section 504. The webs 506,
according to this embodiment, run perpendicular between the front
section 502 and the rear section 504. The webs 506 may be spaced
four inches (+/-) from the end of the stretcher unit 500. To
provide cores that line up, each web 506 has a pair of alternating,
adjacent lugs 508. The lugs 508 extend above the surface of the
stretcher unit 500 and allow the stretcher units to be stacked in a
staggered fashion without the lugs 508 interfering with the web of
a successive layer of stretcher units.
[0030] A first lug of the pair of lugs is coupled against a first
surface of a first web and an inner surface of the rear section. A
second lug of the pair of lugs is coupled against a second surface
of the first web and the inner surface of the front section. A
second pair of lugs for the stretcher unit has a first lug of the
second pair coupled against a first surface of a second web and an
inner surface of the front section. A second lug of the second pair
of lugs is coupled against a second surface of the second web and
the inner surface of the rear section. Each of the lugs in the
first pair of lugs is positioned on alternating sides of the first
web. Each lug of the second pair of lugs is also positioned on
alternating sides of the second web; however, the lugs are on
opposite sides from the first web. This allows the successive layer
of stretcher units to rest on the stretcher unit and allows the
lugs 508 of the stretcher unit 500 to protrude into the cells of
the successive layer of stretcher units without interfering with
the lugs of the successive layer of stretcher units.
[0031] When the wall is constructed the stretcher units may be
staged half way off-center for each successive row. This allows the
alternating pairs of lugs to straddle the webs of successive rows
of stretcher units. The stretcher unit 500 is supported in the
lateral direction by a lug positioned between the inner surface of
the front or rear section and the web. The constructed wall locks
together by the protruding lugs extending into the cells and
straddling the webs of successive rows of stretcher units above and
below the stretcher unit.
[0032] The stretcher unit 500 may also have a beveled profile on
the outer surface of the front section and rear section. The
stretcher unit 500 may also have a chamfered side edge for coupling
to adjacent units. In addition, the stretcher unit may have a
knock-out portion for producing a bonding-beam. These features are
similar to those previously described herein with respect to the
exemplary embodiment disclosing the exemplary stretcher unit 400
with angled webs.
[0033] An exemplary embodiment of the invention with beveled lug
profiles is shown in FIGS. 6A, 6B, 6C, and 6D. The exemplary
embodiments 600 may include a beveled lug profile 602. The lugs 604
have a beveled surface adjacent to the outer surface of the front
section 606 and the rear section 608. The beveled profile aids in
the stacking of successive stretcher units. The weight of
successive stretcher units pushing down centers the unit into the
correct resting position. The beveled lug profiles 602 help to
prevent successive stretcher units from becoming stuck or partially
resting on the lug of lower stretcher units. In addition to a
beveled profile on the surface of the lug facing the outer surface
of the front section and the rear section, the lugs may also have a
beveled surface adjacent to the web (not shown in Figures). The
additional beveled profile aids in stacking and aligning the face
shells of the stretcher unit as previously discussed.
[0034] A corner unit 700 according to an exemplary embodiment of
the invention is shown in FIGS. 7A, 7B, and 7C. The corner unit 700
has a front section 702 and a rear section 704. The corner unit 700
also has a side section 706 coupling the front section 702 and the
rear section 704. One or more webs 708 couple the front section 702
to the rear section 704. The corner unit 700 may be positioned at
the corner of a constructed wall as shown in FIG. 2. The side
section 706 provides a uniform appearance at the end of a row of
units and provides support for successive rows of units. The corner
units may be stacked alternating by 90 degrees for each row. This
provides a lacing of rows between two linear portions of the
structure. The cell of the corner units 700 may be filled with
concrete to lock the corner units 700 together.
[0035] The web 708 is spaced to receive lugs from a previous row of
stretcher units off-set by half a unit length. The web is spaced
within the corner unit so as to align on top of the web of a
previous row of stretcher units allowing the lugs of the previous
row of stretcher units to straddle the web. The corner unit may
also be used in the construction of a linear position of a wall as
shown in FIG. 3. The corner unit 700 may also have a beveled or
chamfered profile on the outer surface of the front section 702 and
rear section 704. The corner unit 700 may also have a chamfered
side edge for coupling to adjacent units. In addition, the
stretcher unit may have a knock-out portion for producing a
bonding-beam. These features are similar to those previously
described herein with respect to the exemplary embodiment
disclosing the exemplary stretcher unit 400 with angled webs.
[0036] The stretcher units may assemble into a linear wall
structure 800 as shown in FIGS. 8A and 8B. The linear cells 802 of
the stretcher and/or corner units produce a vertical post. The
vertical posts typically may be reinforced with a reinforcement
member, for example, steel rebar. The linear cells 802 of the
stacked stretcher units provide a more consistent size and are
aligned linearly. When concrete is poured into the cells the more
consistent size of the linear cell makes it less difficult to
install reinforcement members in the cores to form the vertical
posts. In addition, the more uniform cell dimensions may make it
less difficult to fill the voids within the cell. Many conventional
dry stack block systems may provide little or no damming capacity
when filling the cells of a dry stack block wall structure.
[0037] FIG. 9 is a perspective view of the stretcher unit stacked
according to an exemplary stacking embodiment 900. The dimensions
and structure of the stretcher unit provide the ability to stack a
single column of units. By alternating each successive unit by 180
degrees the next stretcher unit may be stacked on top of a
successive unit. The lugs of the stretcher units align in the cells
of each successive stretcher unit.
[0038] Modifications may be made to fit particular operating
requirements and environments as will be apparent to those skilled
in the art, the invention is not considered limited to the examples
chosen for purposes of disclosure, and covers all changes and
modifications which do not constitute departures from the true
spirit and scope of this invention. Modifications and substitutions
by one of ordinary skill in the art are considered to be within the
scope of the present invention.
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