U.S. patent application number 11/819245 was filed with the patent office on 2007-11-01 for drywall construction method and apparatus.
Invention is credited to Clifford E. Van Steinburg.
Application Number | 20070251182 11/819245 |
Document ID | / |
Family ID | 38421238 |
Filed Date | 2007-11-01 |
United States Patent
Application |
20070251182 |
Kind Code |
A1 |
Van Steinburg; Clifford E. |
November 1, 2007 |
Drywall construction method and apparatus
Abstract
Means for and a method of erecting block drywall wherein the
blocks, or bricks, are, for the most part, rectangular in
appearance and each provided, on their undersides, with a
longitudinal and centrally oriented cavity extending the full
length of each block and leaving longitudinal, horizontal, contact
areas on each side of the cavity for seating on an underlying block
in a wall construction, the upper sides of each block being
provided with a horizontal and centrally located protuberance
extending the full length of the block, there being longitudinal
seating areas along the top side of each block situated to
cooperate with the underside seating areas on each side of a
similar block seated thereon, the cavities and protuberances of the
blocks constituting symmetrically opposed mating surfaces
facilitating the staking of blocks, one upon another and slideable
longitudinally with respect to each other in a vertical drywall
construction, the blocks of each row may be provided with centrally
located and horizontally and longitudinally spaced holes extending
vertically and completely through each block, the longitudinal
spacing of the holes being such that when blocks are stacked in
standard staggered offset layer relationship in an erected wall the
holes are coincident from row to row accommodating the insertion of
locating pins fixing the longitudinal displacement of blocks of one
row to each of vertically adjacent rows in a completed wall
construction, in order to provide greater wall stability space may
be provided between the protuberances and the undersides of
cavities of blocks seated thereon to accommodate a belt, running
lengthwise of a row of blocks, the belt being provided with holes
coinciding with the coincident holes of stacked horizontal rows to
allow the insertion of locating pins extending vertically from
centrally of one block to a position centrally of a vertically
adjacent block mated therewith, the pins each being of a length
approximating the height of a block.
Inventors: |
Van Steinburg; Clifford E.;
(Scarborough, CA) |
Correspondence
Address: |
Ralph A. Dowell of DOWELL & DOWELL P.C.
2111 Eisenhower Ave
Suite 406
Alexandria
VA
22314
US
|
Family ID: |
38421238 |
Appl. No.: |
11/819245 |
Filed: |
June 26, 2007 |
Current U.S.
Class: |
52/586.1 |
Current CPC
Class: |
E04B 2002/0208 20130101;
E04B 2002/0245 20130101; E04B 2/06 20130101 |
Class at
Publication: |
052/586.1 |
International
Class: |
E04B 2/00 20060101
E04B002/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 15, 2006 |
CA |
2537356 |
Claims
1. Means for use in constructing a mortarless block wall utilizing
blocks laid in rows stacked vertically wherein the blocks are each
provided with substantially elongated-rectangular configurations,
each block being provided with, on its underside, a laterally
central cavity extending for the full length of the block and
leaving flat longitudinal side areas for accommodating the seating
of one block on another, each block being further provided with an
upper side protuberance, extending for the full length of the
block, symmetrically opposed to the lower cavity of the block to
mate with the cavity of a similar block seated thereon, there being
flat seating areas provided on each longitudinal side of the
protuberance of each block to cooperate with the flat longitudinal
underside areas of a similar block seated thereon.
2. Means for use in constructing a motarless block wall, as claimed
in claim 1, wherein each block is provided with holes, passing
vertically therethrough, located centrally of the block and spaced
to coincide with holes in a block seated thereon and offset
longitudinally in staggered block wall construction and pins,
adapted to be insertable into the holes and of a length
approximating the height of one block.
3. Means for constructing a motarless block wall, as claimed in
claim 2 wherein an elongated belt is provided with holes spaced
longitudinally of the belt and spaced to coincide with the vertical
holes provided in the blocks, when the blocks are laid in the
staggered layer format, for securing the belt and block layers
against horizontal displacement with respect to each other, there
being a space provided between each protuberance and mating cavity
to accommodate the insertion of the belt running longitudinally of
a row of blocks.
4. Means for use in constructing a mortarless block wall utilizing
blocks laid in a rows stacked vertically wherein the blocks are
each provided with substantially elongated-rectangular
configurations, each block being provided with, on its underside, a
laterally central cavity extending for the full length of the block
and leaving flat longitudinal side areas for accommodating the
seating of one block on another, each block being further provided
with an upper side protuberance, extending for the full length of
the block, symmetrically opposed to the lower cavity of the block
to mate with the cavity of a similar block when seated thereon,
there being flat seating areas provided on each longitudinal side
of the protuberance of each block to cooperate with the flat
longitudinal underside areas of a similar block seated thereon.
5. The means claimed in claim 4 wherein a clearance space is
provided between the upper side of a protuberance and the lower
side of a cavity, seated thereover, to accommodate the insertion of
a elongated belt between layers of mated blocks.
6. Means for constructing a mortarless block wall, as claimed in
claim 5, wherein the belt is provided with holes longitudinally
spaced to coincide with vertical holes provided through each block
when the blocks are laid in abutting relationship in an elongated
row and pins adapted to be insertable into the coincident holes to
limit the longitudinal and lateral movement of the belt with
respect to blocks in a row in a constructed wall.
7. Means for constructing a mortarless block wall as claimed in
claim 5 wherein the length of the pins is approximately equal to
the height of a block.
8. Block for drywall construction wherein the blocks are, for the
most part, rectangular boxlike in appearance and each provided, on
their underside, with a longitudinal and centrally oriented cavity
extending the full length of each block and leaving longitudinal,
horizontal, contact areas on each side of the cavity for seating on
an underlying block in a wall construction, the upper sides of each
block being provided with a horizontal and centrally located
protuberance extending the full length of the block there being
longitudinal seating areas along the top side of each block
situated to cooperate with the underside seating areas on each side
of a similar block seated thereon, the cavities and protuberances
of the blocks constituting symmetrically opposed mating surfaces
facilitating the staking of blocks, one upon another and slideable
longitudinally with respect to each other in a vertical drywall
construction,
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to block-type drywall construction
and, to a drywall construction and the method for carrying it out.
The constructed wall is comprised by vertically stacked horizontal
rows of blocks designed to be, essentially, self supporting, easily
constructed and economical insofar as material and labour costs are
concerned.
[0003] 2. Brief Discussion of the Related
[0004] Drywall construction is used generally for low height walls
and takes the form of a wall constructed of longitudinal rows, the
rows of unitary building units or blocks which are stacked
vertically to provide a self supporting wall structure, a securing
cement, or mortar, being dispensed with.
[0005] U.S. Pat. No. 5,048,250--Ellias, issued Sep. 17, 1991, is
directed to a building block per se which is designed for stacking
in a drywall structure. The blocks are provided with vertically
oriented holes, which in stacking are vertically aligned through
row layers, through which rods may be passed, after the wall is
constructed, to provide reinforcement of the structure.
[0006] U.S. Pat. No. 4,426,815--Brown, issued Jan. 26, 1984, is
directed to a mortarless concrete building block provided with key
means locking one layer of blocks to the underlying or overlying
next layer. Here again reinforcing rods may be used for added
strength.
[0007] U.S. Pat. No. 2,199,112--O'Leary, issued Apr. 30, 1940, is
directed to an insulated building block having, in one instance, a
simulated brick construction surface being applied to the face of
the block.
[0008] U.S. Pat. No. 2,006,462--Kupper, issued Jul. 2, 1935, is
directed to a miniature building system wherein individual building
blocks are mounted on and secured by vertical rods passing
consecutively through layers of the blocks.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a drywall construction
method and means facilitating ease of construction while, at the
same time, providing a sturdy structure. The construction block,
according to the invention, is similar to a standard size brick
modified somewhat to accommodate the features and aims of the
present invention.
[0010] The construction block, upon which the present description
is primarily based, is in the form of an elongated box provided
with a top surface exhibiting a dome-like longitudinal and central
configuration holes and a symmetrically opposed, longitudinally
disposed under surface. In addition a series of longitudinally
displaced vertically oriented holes may be provided passing
vertically through the block with the holes symmetrically situated
so that the holes of vertically stacked and offset block rows will
align or coincide with the holes of similar and vertically and
offset stacked rows. In the case of a block provided with three
such holes, the centre hole of one block will coincide vertically
with the butting ends of the blocks in the vertically stacked and
horizontally offset rows immediately above and below that
particular center hole.
[0011] An additional feature of the invention may be the use of
short pin members, for instance in the form of tubes, which are
dimensioned to fit snugly into the holes in the blocks. The length
of the pin member is preferably substantially equal to the vertical
height of a block and is inserted into the hole of a block to the
approximate extent of half its length, the other half of the pin
member acting as a locating pin upon which the block of a
subsequent horizontal row of blocks is laid. The pin members act as
means for securing the block against lateral and horizontal
displacement with respect to each other in one row and with respect
the blocks of adjacent vertically stacked rows of blocks. In
addition, the pins, in view of their snug fits in the holes of the
blocks, provide an additional degree of vertical stability. When
the pins are tubular in form, vertical reinforcing rods may be
readily inserted through a number of laid rows of blocks to
increase the vertical rigidity of the wall.
[0012] The ends, or the abutting surfaces, of the blocks in a
horizontal layer can be provided with vertically oriented cutouts
corresponding to half a hole which, in conjunction with an abutting
brick, form a composite vertical hole which is utilized by inserted
pin means to align and maintain the alignment of abutting block
ends in a horizontal layer. In addition, the inserted pin acts as a
means of securing the block rows against lateral and longitudinal
movement between the blocks and a vertically adjacent layer of
blocks. Alternately, the vertical holes supplied in the block may
be displaced symmetrically with respect to the ends of the blocks
so that the holes in one row of blocks are coincident with holes in
a vertically adjacent row of blocks, the coincidence being
maintained throughout the, vertically stacked, horizontal rows of
blocks in a completed wall.
[0013] This type of construction reduces labour costs in the
building of walls, is economical and, in view of the fact there are
no rigid joints the wall may be subjected to considerable
vibrational stress without consequent cracking and deterioration
thus rendering the construction useful for earthquake prone
areas.
[0014] According to the invention, the blocks are each provided, on
their upper surfaces, with a raised, longitudinally oriented,
laterally central, portion preferably extending for the full length
of the block and having, preferably, a flat, longitudinally
oriented, upper surface area. The lower surfaces of each block is
provided with symmetrically opposed and contoured, longitudinally
oriented, cutout which mates with the upper surface of a similar
block positioned therebeneath in a vertically adjacent row of
blocks to form an interlock resisting relative lateral movement
between adjacent rows of blocks in a constructed wall. The blocks
of a row are longitudinally moveable with respect to the blocks of
a vertically adjacent and mating row of blocks. In order to prevent
longitudinal movement of blocks in one horizontal row with respect
to the blocks in vertically adjacent row of blocks, pins, mating
with the holes in the blocks or the composite holes between the
ends of abutting blocks, may be inserted in the holes of blocks in
a row leaving extended ends which insert into coincident holes of a
vertically adjacent row of blocks to limit the longitudinal
movement of one layer of blocks with respect to an vertically
adjacent, mating, row of blocks.
[0015] In order to facilitate construction, the pins are
preferable, in overall length, to be slightly less than the
distance between vertical centers of adjacent rows of blocks.
Although it is possible to use longer pins difficulties may arise
in assembling multiple row walls when the pins are a greater length
than the preferred length. Furthermore, the repair of a wall can be
greatly impeded when the pins employed in construction are greater
in length than the preferred length.
[0016] In order to provide greater wall integrity, a longitudinally
oriented belt may be inserted between the vertically stacked rows
of blocks and enclosed between the mating upper and lower surfaces
of blocks to assist in assuring longitudinal alignment of blocks in
each row and the row vertically adjacent thereto. In order to
accommodate such a belt the upper raised surface of a block can be
designed to be proud of the lower surface of the cutout of a mated
block so that an internal space is provided between the mating
surfaces to accommodate the belt.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIGS. 1, 2 and 3 show a top view, a side view and a
cross-sectional view respectively of a building block according to
the present invention,
[0018] FIGS. 4, 5 and 6. show a top view, a side view and a
cross-sectional view respectively of a modified version of a
building block according to the present invention,
[0019] FIG. 7 shows in end view, two building blocks, in exploded
view, vertically staked and oriented as, they would be situated in
a vertical wall construction of two vertically stacked rows of
blocks,
[0020] FIG. 8 shows two blocks, as illustrated in FIG. 7, in
cross-sectional and unexploded view with locating pins inserted in
coincident vertical holes of the blocks rows. FIG. 8 also shows a
belt 9b, better shown in FIGS. 9 and 10, inserted between the
blocks, the belt running longitudinally of the blocks as shown in
FIGS. 9 and 10,
[0021] FIG. 9 shows an exploded view of a wall construction based
on the use of blocks according to FIGS. 1, 2 and 3 and
[0022] FIG. 10 shows an exploded view of a wall construction based
on the use of blocks according to FIGS. 4, 5 and 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] FIGS. 1, 2 and 3 show a building block 1, for instance a
baked clay or concrete block, according to the invention and
adapted for use in the construction of a vertical, motarless, wall
(drywall). The block 1, as shown in FIGS. 1 and 2, is, for the most
part, an elongated rectangular box form which, as is illustrated
best by FIG. 3, provided with a longitudinal, transversally
central, lower cavity 3 which extends linearly for the full length
of the block, the cavity 3, preferably, being terminated, on each
lateral side, with extreme lower flat, portions 2 corresponding to
the lower surface of the block and an inner and upper flat surface
3 connected to the lower flat portions 2 by linearly sloping sides
4.
[0024] On the upper surface of the block 1 a symmetrically opposed,
raised and linearly elongated surface protuberance 5 is provided
and proportioned to mate with the underside cavity 3 of a further
correspondingly formed block, stacked vertically thereon, so that
the flat portions 2 of the corresponding block rest on the outer,
top, flat portions 6 corresponding to the top surface of the block
thus providing firm seating and mating surfaces. It is preferable
that the flat surface 3 of the cavity of each block is raised
sufficiently, with respect to the surfaces 2, to ensure secure
stable seating of the flat surfaces 2 and 6. The top surface 5 of
the protuberance is joined to the flat portions 6 by sloping
surfaces 7. The sloping surfaces 7 may be, alternately, be
substantially vertical but such an orientation may add difficulty
in the stacking of layers of blocks.
[0025] It should be noted here that the contours of the mating
cavities, protrusions and surfaces can be varied with respect to
what has been described herein. It is essential however, in
vertical drywall construction, designed to be essentially self
supporting, that the mating surfaces, when assembled, automatically
provide for substantially true vertical alignment between
vertically stacked, horizontal, rows of blocks.
[0026] It should be noted here that the surface 3 of the lower
cavity of a block can be raised sufficiently, with respect to flat
portions 2 to make room for a longitudinal belt to be inserted
between two layers of blocks as will be referred to in greater
detail with respect to FIGS. 9 and 10.
[0027] The blocks 1 can each be provided with vertical holes 11,
laterally central of the block and extending fully from the lower
surface 3 to the upper surface 5 of each block. The holes 11 may be
located longitudinally central of each block and at each end
thereof, the end holes 11a being in the form of a vertical cutout
forming one limiting surface of a composite vertical hole, the
vertical hole being completed by a similar block end abutted
thereagainst in a horizontal row of blocks. As shown in FIG. 4 the
vertical holes can be located midway between the ends and centers
of each block. Other holes arrangements can be used so long as the
holes of vertically and horizontal conventionally staggered layers
of blocks are coincident. Such coincident arrangements being shown
in FIGS. 9 and 10.
[0028] FIG. 7 illustrates an exploded stacked arrangement of two
blocks 1, 1 wherein the opposed mating surfaces 2 and 6 are spaced
to show the contour of the mating surfaces more clearly. FIG. 8
shows sectional end views of two fully seated blocks 1a, 1b with
three stabilizing pins 9a, 9b, 9c inserted into the coincident
holes 11 of the two blocks, one pin 9a having a half-pin length
part projecting below block 1a, a pin 9b extending from midway of
block 1a to midway of block 1b and the third pin 9c extending from
midway of block 1b to project there above for half its length The
pins 9 stabilize the vertically stacked rows of blocks against
lateral toppling and against relative longitudinal movement with
respect to each other.
[0029] FIG. 9 shows an exploded view two longitudinal rows of
blocks 1a and 1b in stacked vertical arrangement and longitudinally
staggered relationship wherein the blocks are each provided with
holes 11 located midway between the longitudinal centers and the
ends of each block 1 thus facilitating the respective longitudinal
staggering of vertically adjacent horizontal rows of blocks. In
this configuration a belt 10, provided with a series of
longitudinally spaced holes 12, coinciding with coincident block
holes, is placed between the vertically stacked rows of blocks and
accommodated in the space allowed therefore between the upper faces
5 of the lower row and the lower cavity faces 3 of the upper layer
of blocks. Pins 9, when assembled, will extend from approximately
midway of the lower layer to substantially midway of the upper
layer of blocks. This arrangement of rows of blocks is, of course,
repeated vertically throughout the constructed wall.
[0030] FIG. 10 shows an arrangement similar to that described in
regard to FIG. 9, differing only in the location of holes 11 in the
blocks and the accommodating and coinciding holes 12 in belt 10. In
this arrangement every other horizontally located hole 11a, in each
horizontal row of blocks, is a composite hole formed between the
abutting ends of blocks in that row.
[0031] Although preferred embodiments of the invention have been
described further variations and modifications may be made without
departing from the spirit and scope of the invention which is
defined in the claims appended hereto.
* * * * *