U.S. patent application number 12/610819 was filed with the patent office on 2010-02-25 for stacking masonry block system with transition block and utility groove running therethrough.
Invention is credited to Daniel O'Connor.
Application Number | 20100043335 12/610819 |
Document ID | / |
Family ID | 41695027 |
Filed Date | 2010-02-25 |
United States Patent
Application |
20100043335 |
Kind Code |
A1 |
O'Connor; Daniel |
February 25, 2010 |
STACKING MASONRY BLOCK SYSTEM WITH TRANSITION BLOCK AND UTILITY
GROOVE RUNNING THERETHROUGH
Abstract
A masonry block system that employs blocks with unique surfaces,
top, bottom, and transition, and a locking starter rail for
placement below the block wall. The surfaces of the block and the
shape of the starter rail are configured so as to lock together,
providing a wall system. The system can either be mortarless
wherein grout-like material is placed within the blocks to provide
a monolithic system. A method of making and installing and various
parts, such as the starter rail and block are also disclosed.
Inventors: |
O'Connor; Daniel;
(Millbrook, NY) |
Correspondence
Address: |
SCHMEISER, OLSEN & WATTS
22 CENTURY HILL DRIVE, SUITE 302
LATHAM
NY
12110
US
|
Family ID: |
41695027 |
Appl. No.: |
12/610819 |
Filed: |
November 2, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11159049 |
Jun 22, 2005 |
7610730 |
|
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12610819 |
|
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Current U.S.
Class: |
52/592.6 ;
52/604 |
Current CPC
Class: |
E04C 1/00 20130101; E04B
2/16 20130101; E04B 2/26 20130101; E04B 2002/0208 20130101 |
Class at
Publication: |
52/592.6 ;
52/604 |
International
Class: |
E04B 2/02 20060101
E04B002/02; E04B 2/00 20060101 E04B002/00; E04B 2/14 20060101
E04B002/14; E04C 1/00 20060101 E04C001/00 |
Claims
1. A masonry block comprising: a first surface configured to mate
with a bottom surface of a first block, wherein the shape of said
bottom surface of said first block corresponds to the shape of said
first surface; a second surface configured to mate with a top
surface of a second block, wherein the shape of said top surface of
said second block corresponds to the shape of said second surface;
a third surface having a shape which corresponds to the shapes of
said first surface and said second surface; at least one planar
surface positioned between said first surface and said third
surface; and wherein said second surface and said third surface are
coplanar.
2. The block of claim 1, further comprising: a uniform opening
extending throughout said block, wherein said uniform opening holds
an object.
3. The block of claim 1, wherein said first surface and said second
surface are coextensive.
4. The block of claim 1, wherein mating between said third surface
and said top surface of said first block forms an intersection.
5. The block of claim 1, wherein said block is adjacently
stackable.
6. The block of claim 1, wherein said third surface intersectingly
engages said top surface at any point along said second block.
7. The block of claim 1, wherein at least one vertical opening is
located proximate said first surface.
8. The block of claim 7, wherein a flowable, hardenable material is
placed within said vertical opening.
9. The block of claim 1, wherein said second surface has a raised
intermediate portion that interlocks in at least one horizontal
direction with a raised intermediate portion of said top surface of
said second block.
10. A stacking masonry block system comprising: a plurality of
standard blocks configurable in a stackable row, each of said
standard blocks having a top surface and a bottom surface, wherein
said bottom surface of each of said standard blocks is configured
to mate with said top surface of each of said standard blocks,
wherein each of said plurality of standard blocks contain a cavity
such that said stackable row has at least one vertical opening
therethrough; and a plurality of transition blocks configurable in
said stackable row, each transition block having a first surface, a
second surface, and a third surface, wherein said second surface of
each of said transition blocks is configured to mate with said top
surface of each of said standard blocks, said first surface is
configured to mate with said bottom surface of each of said
standard blocks, and said third surface is configured to
intersectingly mate with said top surface of each of said standard
blocks.
11. The system of claim 10, wherein each of said plurality of
standard blocks and each of said plurality of transition blocks
have a horizontal groove located therein.
12. The system of claim 11, wherein said groove is aligned with
said groove of an adjacent block.
13. The system of claim 10, further comprising: a plurality of
capstone blocks configurable in said stackable row, each of said
plurality of capstone blocks having a flat upper surface, wherein
each of said plurality of capstone blocks have a lower surface
configured to mate with said top surface of each of said standard
blocks and configured to mate with said first surface of each of
said transition blocks.
14. The system of claim 10, wherein a structure is defined by a
combination of said standard blocks, said transition blocks, and
said capstone blocks.
15. The system of claim 10, wherein a flowable, hardenable material
is placed within said at least one vertical opening to secure said
plurality of blocks to a starter rail.
16. A masonry block system comprising: a plurality of blocks,
configurable in a stackable row, each of said plurality of blocks
having a top surface and a bottom surface, wherein said bottom
surface of each of said plurality of blocks is configured to match
with the top surface of each of said plurality of blocks, wherein
each of said plurality of blocks contains a cavity such that said
stackable row has a vertical opening therethrough; and a starter
rail, configured to mate with said bottom surface of each of said
plurality of blocks and configured to be in communication with said
vertical opening, said rail including at least a first longitudinal
planar surface and a second longitudinal planar surface
longitudinally connected to the first longitudinal planar surface,
wherein an angle between said first longitudinal planar surface and
said second longitudinal planar surface is acute and forms a void
when one of the said plurality of blocks is placed over said
starter rail, wherein the first longitudinal planar surface is
co-planar to the base of the one of the said plurality of blocks
when the one of the said plurality of blocks is placed over said
starter rail, and wherein the bottom of said void has a larger
width than the width of the vertical opening, such that when
hardenable, flowable material is poured into said opening and void
of said starter rail, movement of the blocks is prevented; an
opening located proximate said top surface, said opening extending
throughout said plurality of blocks; and wherein at least one of
said plurality of blocks has a third surface configured to mate
with said top surface to form an intersection.
17. The system of claim 16, wherein said opening is separated by at
least one vertical opening.
18. The system of claim 16, wherein said opening is a channel
running through each of said plurality of blocks, further wherein
said channel coextensive between said plurality of blocks.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of patent
application Ser. No. 11/159,049 filed Jun. 22, 2005.
FIELD OF INVENTION
[0002] This invention relates generally to the field of masonry
block construction. More particularly, the invention relates to a
masonry block system that employs a dry stacking interlocking block
system with a unique starter device; various elements of the
system; and, a method of installation.
BACKGROUND OF INVENTION
[0003] Current methods and systems for masonry block construction
have several advantages and disadvantages when compared to
comparable cast-in-place concrete construction.
[0004] Masonry construction does not typically require formwork,
both in erection and teardown that is found in concrete
construction. Masonry construction also typically reaches design
strengths quicker than comparable concrete construction. In
general, masonry construction is less costly in material and labor
costs than concrete construction.
[0005] Conversely, masonry block construction typically requires
extensive layout time and labor to properly and accurately start
the masonry construction. Further, the time, labor, and material in
the installation of block, including mortar, requires continual
adjustment and verification that the block wythes are plumb, level,
and in alignment. Often too, masonry block construction does not
have the ultimate strength of concrete construction.
[0006] Accordingly, there is a need for a masonry block system that
offers advantages and improvements over current existing concrete
and masonry block construction systems and methods.
SUMMARY OF INVENTION
[0007] The present invention provides a stacking masonry block
system.
[0008] A first aspect of the invention provides a masonry block
comprising a first surface configured to mate with a bottom surface
of a first block, wherein the shape of said bottom surface of said
first block corresponds to the shape of said first surface, a
second surface configured to mate with a top surface of a second
block, wherein the shape of said top surface of said second block
corresponds to the shape of said second surface, a third surface
having a shape which corresponds to the shapes of said first
surface and said second surface, at least one planar surface
positioned between said first surface and said third, and wherein
said second surface and said third surface are coplanar.
[0009] A second aspect of the invention provides a stacking masonry
block system comprising a plurality of standard blocks configurable
in a stackable row, each of said standard blocks having a top
surface and a bottom surface, wherein said bottom surface of each
of said standard blocks is configured to mate with said top surface
of each of said standard blocks, wherein each of said plurality of
standard blocks contain a cavity such that said stackable row has
at least one vertical opening therethrough, and a plurality of
transition blocks configurable in said stackable row, each
transition block having a first surface, a second surface, and a
third surface, wherein said second surface of each of said
transition blocks is configured to mate with said top surface of
each of said standard blocks, said first surface is configured to
mate with said bottom surface of each of said standard blocks, and
said third surface is configured to intersectingly mate with said
top surface of each of said standard blocks.
[0010] A third aspect of the invention provides a masonry block
system comprising a plurality of blocks, configurable in a
stackable row, each of said plurality of blocks having a top
surface and a bottom surface, wherein said bottom surface of each
of said plurality of blocks is configured to match with the top
surface of each of said plurality of blocks, wherein each of said
plurality of blocks contains a cavity such that said stackable row
has a vertical opening therethrough, a starter rail, configured to
mate with said bottom surface of each of said plurality of blocks
and configured to be in communication with said vertical opening,
said rail including at least a first longitudinal planar surface
and a second longitudinal planar surface longitudinally connected
to the first longitudinal planar surface, wherein an angle between
said first longitudinal planar surface and said second longitudinal
planar surface is acute and forms a void when one of the said
plurality of blocks is placed over said starter rail, wherein the
first longitudinal planar surface is co-planar to the base of the
one of the said plurality of blocks when the one of the said
plurality of blocks is placed over said starter rail, and wherein
the bottom of said void has a larger width than the width of the
vertical opening, such that when hardenable, flowable material is
poured into said opening and void of said starter rail, movement of
the blocks is prevented, an opening located proximate said top
surface, said opening extending throughout said plurality of
blocks, and wherein at least one of said plurality of blocks has a
third surface configured to mate with said top surface to form an
intersection.
[0011] A fourth aspect of the invention provides a method of
stacking interlocking masonry blocks.
[0012] The foregoing and other features of the invention will be
apparent from the following more particular description of various
embodiments of the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0013] Some of the embodiments of this invention will be described
in detail, with reference to the following figures, wherein like
designations denote like members, wherein:
[0014] FIG. 1 depicts an exploded perspective view of an embodiment
of the interlocking masonry block system, in accordance with the
present invention;
[0015] FIG. 2A depicts a top view of an embodiment of a locking
starter device, in accordance with the present invention;
[0016] FIG. 2B depicts an end sectional view of an embodiment of a
locking starter device, in accordance with the present
invention;
[0017] FIG. 3A depicts a top view of an embodiment of a standard
masonry block, in accordance with the present invention;
[0018] FIG. 3B depicts an end view of an embodiment of a standard
masonry block, in accordance with the present invention;
[0019] FIG. 4A depicts a perspective view of an embodiment of a
transition masonry block, in accordance with the present
invention;
[0020] FIG. 4B depicts a side view of an embodiment of a transition
masonry block, in accordance with the present invention;
[0021] FIG. 4C depicts a bottom view of an embodiment of a
transition masonry block, in accordance with the present
invention;
[0022] FIG. 4D depicts a perspective view of an embodiment of an
assembly of a plurality of masonry blocks, in accordance with the
present invention;
[0023] FIG. 4E depicts an end view of an embodiment of an assembly
of a plurality of masonry blocks, in accordance with the present
invention;
[0024] FIG. 5A depicts a top view of an embodiment of a corner
masonry block, in accordance with the present invention;
[0025] FIG. 5B depicts an end view of an embodiment of a corner
masonry block, in accordance with the present invention;
[0026] FIG. 6A depicts a top view of an embodiment of a capstone
masonry block, in accordance with the present invention;
[0027] FIG. 6B depicts an end view of an embodiment of a capstone
masonry block, in accordance with the present invention;
[0028] FIG. 7A depicts a perspective view of an embodiment of a
standard masonry block having a groove, in accordance with the
present invention;
[0029] FIG. 7B depicts an end view of an embodiment of a standard
masonry block having a groove, in accordance with the present
invention;
[0030] FIG. 8A depicts a perspective view of an embodiment of a
transition masonry block having a groove, in accordance with the
present invention;
[0031] FIG. 8B depicts an end view of an embodiment of a transition
masonry block having a groove, in accordance with the present
invention;
[0032] FIG. 8C depicts a top view of an embodiment of a transition
masonry block having a groove, in accordance with the present
invention;
[0033] FIG. 9A depicts a perspective view of an embodiment of an
assembly of a plurality of masonry blocks having grooves, in
accordance with the present invention;
[0034] FIG. 9B depicts a side view of an embodiment of an assembly
of a plurality of masonry blocks having a groove, in accordance
with the present invention;
[0035] FIG. 10A depicts a perspective view of an embodiment of a
masonry block having scallops, in accordance with the present
invention;
[0036] FIG. 10B depicts an end view of an embodiment of a masonry
block having scallops, in accordance with the present
invention;
[0037] FIG. 10C depicts a top view of an embodiment of a masonry
block having scallops, in accordance with the present invention;
and
[0038] FIG. 11 depicts a close-up sectional view of a portion of
the interlocking masonry block system, in accordance with the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0039] Although certain embodiments of the present invention will
be shown and described in detail, it should be understood that
various changes and modifications may be made without departing
from the scope of the appended claims. The scope of the present
invention will in no way be limited to the number of constituting
components, the materials thereof, the shapes thereof, the relative
arrangement thereof, etc., and are disclosed simply as an example
of an embodiment. Although the drawings are intended to illustrate
the present invention, the drawings are not necessarily drawn to
scale.
[0040] Turning to the figures, an exploded perspective view of an
embodiment of the invention is depicted in FIG. 1, while FIGS. 2-4
show various details of the invention.
[0041] FIG. 1 shows a typical foundation footer 60, often made of
concrete, having a top surface 61. Resting and bearing on the
footer 60 is a system 10 of the invention. A starter element 20 and
a plurality of blocks 40 are placed together on the footer 60. Upon
satisfactory installation of the starter elements 20 and the blocks
40, flowable, hardenable material 70 is subsequently placed within
the cavities 45 (see e.g., FIG. 11) to bond the entire construct
together. In this manner the system 10 is a mortarless, block-type
construct having an increased strength.
[0042] As shown in FIGS. 1, 2A, and 2B, the detail and
configuration, of an embodiment of a starter strip 20 is shown. The
starter strip 20, or element, is typically longitudinal in shape
comprised of a plurality of elongate, planar surfaces. The strip 20
includes a first, or base, longitudinal planar section 21, and a
second longitudinal planar section 22A. There may be additionally a
third longitudinal planar section 22B. Furthermore, the starter
strip 20, or starter rail, may be configured to mate with a bottom
surface 47 of each of a plurality of blocks 40 and may be
configured to be in communication with a vertical opening 45. The
starter strip 20, or starter rail may include at least a first
longitudinal planar surface 21 and a second longitudinal planar
surface 22A longitudinally connected to the first longitudinal
planar surface 21, wherein an angle between the first longitudinal
planar surface 21 and the second longitudinal planar surface 22A is
acute and forms a void when one of the plurality of blocks 40 is
placed over the starter strip 20, or starter rail, wherein the
first longitudinal planar surface 21 is co-planar to the base of
the one of the plurality of blocks 40 when the one of the plurality
of blocks 40 is placed over the starter strip 20, or starter rail.
The bottom of the void has a larger width than the width of the
vertical opening, such that when hardenable, flowable material 70
is poured into opening 45 and void of the starter rail, movement of
the blocks may be prevented.
[0043] Moreover, the base 21 is configured to lay upon the footer
top 61. The base 21 may include a plurality of openings 23 (e.g.,
23A, 23B, etc.) shaped to allow various connectors 30 to connect
the strip 20 to the footer 60. The openings 23 may be holes, slots,
and the like. Similarly, the openings 23 may be spaced and
configured to suitably attach the strip 20 to footer 60. For
example, FIG. 2B shows one method of attachment, wherein the
connectors 30 are a plurality of screws 30 with threads 32 and
washers 21 are drilled into the footer 60 in either pre-drilled
holes or in a self-tapping manner so as to attach the strip 20 to
footer 60. Additionally, the openings 23 are available for allowing
reinforcing bar, mechanical or electrical "stub ups", and the like,
to pass through the base 21. The strip 20 may be made of a suitable
rigid, or semi-rigid, material so that upon its installation the
alignment and placement of strip 20 is maintained so as to allow
accurately subsequent placement of the blocks 40 upon the strip 20.
For example, the strip 20 may be constructed of steel, galvanized
material, stainless steel, cold-rolled steel, composite material,
and the like. The base or first planar surface 21 is co-planar to
the base of at least one of the plurality of blocks 40 when one of
the plurality of blocks 40 is placed over the starter rail 20.
[0044] Various means and methods may be used to attach the strip 20
to the footer 60. While FIG. 2B shows screws 30 as attachment
means, the connectors 30 may be, for example, threaded rod (e.g.,
J-bolts, straight rod, etc.) embedded within the footer 60 and
partially extending above the footer 60. With this means of
attachment, the strip 20 is attached to the plurality of threaded
rod via nuts. Still alternatively, the strip 20 may be attached to
the foundation 60 via a permanent adhesive (e.g., epoxy), and the
like. In other embodiments, if the structural application allows,
the strip 20 may be lightly pinned down, or laid in place, on the
foundation 60, with, for example, aesthetic, light construction,
low walls.
[0045] The second longitudinal planar section 22A and the third
longitudinal planar section 22B are non-parallel with the base 21.
Additionally, the second and third planar sections 22A, 22B may be
non-parallel to each other. Further, the second and third planar
sections 22A, 22B may each form an acute angle, .phi..sub.1 and
.phi..sub.2, respectively, with the base 21. Further, angles
.phi..sub.1 and .phi..sub.2 may, or may not, be equal to each
other.
[0046] It should be apparent that various configurations of planar
sections 21, 22A, 22B are part and parcel of the present invention.
For example, any, or all of the sections 21, 22A, 22B may be less
than entirely solid. That is the sections 21, 22A, 22B may have
various openings. The sections 21, 22A, 22B may be lattice-like in
their construction. The openings (not shown) may exist in order to
allow the ready flow, or passage of flowable, hardenable material
70 throughout the system 10; to allow for additional elements (not
shown) to pass through; to provide a lighter weight strip 20; and
the like. Further, while the embodiment in FIGS. 2A and 2B depict
sections 21, 22A, 22B that are smooth in construction, clearly
appendages, projections, depressions, detents, and the like, can be
added while not diverging from the intent of the invention.
Additionally, starter strip 20 may also mate, correspond, and/or
fit with transition block 140.
[0047] Similarly, various configurations of the strip 20 may be
employed. The strip 20 can come in various lengths of straight
sections. The strip 20 also can be on an angle for constructing
corners. The strip 20, thus, may be any angle. The strip 20 can be
made on a curve, or multiple curves, of any radius. In these
embodiments, the strip 20 can be rigid so that the shape and
configuration is fixed. Alternatively, the strip 20 may be
semi-rigid. That is, the strip 20 may be constructed so that its
shape and configuration may user-adjustable in the field to any
angulation and/or curvature. For example, the strip 20 may have
gaps or other constructs that allows the installer to move, shape,
and bend the strip 20 to the desired configuration. Once installed
to the foundation 60, the strip 20 provides a virtually errorless
method for installing the subsequent blocks 40.
[0048] Turning to FIGS. 3A-6B, several embodiments of blocks 40,
140, 240, and 340 are depicted in detail. FIGS. 3A and 3B depict an
embodiment of what could be termed a "typical" or "standard" block
40, FIGS. 4A-4C depict an embodiment of a transition block 140,
FIGS. 5A-5B depict an embodiment of a corner block 240, which may
also be termed a "L-block," and FIGS. 6A-6B depict an embodiment of
a capstone block 340. While each embodiment of block 40, 140, 240,
and 340 has its particular use, they may share common aspects of
the invention.
[0049] Beginning with FIGS. 3A and 3B, the block 40 has an ultimate
height 41, depth 42, and length 43. The block 40 has two
substantially vertical faces 44 which are exposed to view after
installation. The block 40 includes a first mating area 46 and may
also include a second mating area 47. The block 40 includes a top
bearing surface 51 and a bottom bearing surface 52. Interstitial to
the substantially vertical faces 44 is at least one opening 45.
[0050] Both first mating area 46 and second mating area 47 include
a horizontal face 49, 50 and typically two canted (i.e.,
non-horizontal) surfaces 48A, 48B. Thus, the configuration of the
blocks 40 is such that the first mating area 46 is shaped so as to
mate or fit with the second mating area 47 of an adjacently placed
block 40. More specifically, the canted surfaces 48A, 48B and the
horizontal faces 49, 50 are such that blocks can readily by placed
by the installer easily. Similarly, the first mating area 46 is
configured so as to mate or fit with the starter strip 20, as well.
Furthermore, mating areas 46, 47 need not have a horizontal surface
and two canted surfaces. For example, mating areas 46, 47 may be
curvilinear, such as the shape of a half-moon, or may be polygonal
in design, encompassing, inter alia, a square, rectangular,
trapezoid, and the like. The mating areas 46, 47 may be any form or
any shape so long as the shape of the first mating area 146
corresponds to or can mate with the shape of the second mating area
47. Those with skill in the art will also appreciate that the shape
of the starter strip 20 may also need to correspond with the shape
of mating areas 46, 146, 246, 346. Additionally, it should be
understood that all mating areas may also disclose the surfaces of
the blocks 40, 140, 340 which are in physical communication with
each other.
[0051] The configuration of the strip 20 and blocks 40, 140, 240,
340 make installation much quicker and easier than typical block
construction. For example, continual checking for alignment,
plumbness, etc. is not required, or at the least mitigated
significantly. That is once the starter strip 20 is properly
aligned and attached (fixedly or removably) to the footer 60, all
subsequently aligning activity is abolished, or significantly
mitigated.
[0052] Clearly, the block 40, may be constructed of any suitable
height 41, depth 42, and/or length 43, depending on the particular
requirements needed. For example, in the L-shaped embodiment as
shown in FIGS. 5A and 5B, the first length 243A may be unequal to
the second length 243B.
[0053] Similarly, the mating areas 46, 47 need to be on both the
top and bottom of the block 40. For example, both a first mating
area 46 and second mating area 47 may be present for blocks 40,
140, and 240. Contrastingly, the embodiment depicted in FIGS. 6A
and 6B, termed a "capstone" block 340, have only a second mating
area 347 on the bottom of the block 40. Other embodiments (not
shown) may have only a first mating area 46 on the top of the block
40. That is the bottom of the block 40 may be substantially planar.
Such an embodiment may be used as a header, or lintel, over a
doorway or window opening in the system 10.
[0054] With reference to FIGS. 4A-4E, the transition block 140 has
an ultimate height 141, depth 142, and length 143. Clearly, the
block 140 may be constructed of any suitable height 141, depth 142,
and/or length 143, depending on the particular requirements needed.
The block 140 may have two substantially vertical faces 144 which
may be exposed to view after installation. The block 140 includes a
first mating area 146. Block 140 may also include a second mating
area 147. The block 140 includes a top bearing surface 151 and a
bottom bearing surface 152. Interstitial to the substantially
vertical faces 144 is at least one opening 145.
[0055] Furthermore, block 140 may have a transition mating area
160. The transition mating area 160 may be located proximate the
back end 73 of the block 140, proximate the bottom of the block
140. Transition mating area 160 may include a horizontal face 165
and two canted mating (i.e., non-horizontal) surfaces 161A, 161B.
Thus, the configuration of the block 140 may be such that the
transition mating area 160 is shaped so as to mate or fit with a
first mating area 146 of an intersectingly placed block 140. For
instance, the canted mating areas 161A, 161B and the horizontal
faces 165 mate, correspond, interlock, contact, etc., with
horizontal face 149 and canted surfaces 148A and 148B of a
separate, intersectingly placed block 140 at any location. For
example, the transition mating area 160 of a transition block may
engage, interlock, contact, mate, etc., with a first mating area
46, 146 at any point, regardless of whether the mating forms a
corner or a right angle. In other words, a transition block 140 may
intersect a planar surface or wall at any point along the wall,
expanding the freedom of design and construction. This corner or
intersection configuration may be such that blocks 140 can readily,
uniformly, consistently, and easily be placed, stacked, erected,
and/or constructed by the installer of system 10 using only blocks
140, block 40, block 240, block 340, or a combination thereof. The
plurality of blocks 40, 140, 240, and 340 may form not only a
single, planar wall, but a plurality of planar walls connected to
each other at intersections or corners. In one non-limiting
example, a standard block 40, may be perpendicularly or
intersectingly placed underneath block 140 such that shape of the
transition mating area 160 mates, fits, or corresponds with the
shape of a first mating area 46 of the standard block 40. Moreover,
the transition mating area 160 may form a corner or intersection in
the construction of system 10. The block 140 may interlock, stack,
or mate with other blocks 140 or blocks 40 at both the transition
mating area 160 and second mating area 147.
[0056] FIGS. 4D and 4E depict an embodiment of an assembly of
system 100, wherein a plurality of blocks 40, 140, and 340 are
configured in a stackable row to form a wall or structure. Blocks
40 may be placed onto the starter strip 20, as shown in various
embodiments. Transition block 140 may allow an installer to
quickly, easily, and conveniently create an intersection in the
structure. For example, a transition block 140 may be placed onto a
standard block 40, such that the transition mating area 160 mates
with the first mating area 46 of a standard block 40. The mating of
a transition block 140 with a standard block 40, as shown in FIG.
4D, may create an intersection in the structure. In other
embodiments, a transition block 140 may be used to form a corner in
a structure, wherein the structure is comprised of a plurality of
blocks. Those with skill in the art will appreciate that
intersections or corners formed by the plurality of blocks 40, 140
may not always form right angles (90.degree.). Transition mating
area 160 and the back end 73 of block 140 may be constructed to
allow a turn or corner to form an angle from 0.degree. to
180.degree.. For example, the back end 73 of block 140 may be
angled, such that the transition mating area is also angled. In
addition, the first mating area 146 and block 40 may also be angled
to approximately the same angle such that the mating between
transition mating area 146 and first mating area 46 may correspond,
similar to the description above.
[0057] Ostensibly, the configuration of the blocks 140 may also be
such that the first mating area 146 is shaped so as to mate or fit
with the second mating area 147 of an adjacently placed block 140.
More specifically, the canted surfaces 148A, 148B and the
horizontal faces 149, 150 are such that blocks 140 can readily be
placed by the installer easily. Similarly, the first mating area
146 is configured so as to mate or fit with the starter strip 20,
as well. Furthermore, mating areas 146, 147, 160 need not have a
horizontal surface and two canted surfaces. For example, mating
areas 146, 147, 160 may be curvilinear, such as the shape of a
half-moon, or may be polygonal in design, encompassing, inter alia,
a square, rectangular, trapezoid, and the like. The mating areas
146, 147 may be any form or any shape so long as the shape of the
first mating area 146 corresponds to or can mate with the shape of
the second mating area 147, and in the case of the corner or
"transition" block 140, also the shape of the corner mating area
160.
[0058] Moreover, the first mating area 146 and second mating area
147 may be on both the top and bottom of the block 140. Further,
the transition block 140 may only have a transition mating area 160
on the bottom of the block 140.
[0059] FIGS. 5A and 5B depict an embodiment of a corner or L-block
240, which may be used to form a corner in the system 10. The
corner or edge block 240 has an ultimate height 241, depth 242, and
length 243. Clearly, the block 240 may be constructed of any
suitable height 241, depth 242, and/or length 243, depending on the
particular requirements needed. The block 240 may have two or more
substantially vertical faces 244 which may be exposed to view after
installation. The block 240 includes a first mating area 146. Block
240 may also include a second mating area 247. The block 240 may
also include a top bearing surface 251 and a bottom bearing surface
252. Interstitial to the substantially vertical faces 244 is at
least one opening 245. The corner block 240 may be constructed to
resemble the capital letter L, forming an edge or corner in the
structure of system 10. It may include a first mating area 246 and
a second mating area 247. The second mating area 247 may be
configured to mate with a first mating area 46, 146, of a standard
block 40 and/or transition block 140, respectively.
[0060] FIGS. 6A and 6B depict an embodiment of a capstone block
340, which may form the top row of system 100, wherein a plurality
of blocks 40, 140, 340 form a structure or wall system. The
capstone block 340 has an ultimate height 341, depth 342, and
length 343. Clearly, the block 340 may be constructed of any
suitable height 341, depth 342, and/or length 343, depending on the
particular requirements needed. The block 340 may have two
substantially vertical faces 344 which may be exposed to view after
installation. The block 340 includes a top bearing surface 351 and
a bottom bearing surface 352. Interstitial to the substantially
vertical faces 344 is at least one opening 345. The capstone block
340 may not have a first, or top, mating area to mate with a second
mating area 47, 147 of a block to potentially be placed immediately
on top. The capstone block 340 may only have a capstone mating area
347, configured to mate with a first mating area 46 of a standard
block 40, or a first mating area 146 of a transition block 140.
Ostensibly, the top of the block 340 may not have a first mating
area, resulting in a substantially flat surface, which may form the
top row of system 100. The capstone block 340 may be a component in
the plurality of blocks forming a structure. Moreover, the top of
the capstone block 340, which may be substantially flat, may be
solid, or it may have at least one vertical opening therethrough,
such as cavity 45 to both allow a flowable, hardenable material 70,
such as concrete to flow therethrough, or to allow an installer
access to the row of blocks immediately thereunder. The top surface
of the capstone block 340 may be exposed after installation of
system 10, 100. Furthermore, capstone block 340 may also have a
transition mating area 360, as shown in FIG. 4D, such as to allow
the top row of system 100, or a single capstone block 340, to
intersect at any given point along a planar surface, or along a
portion of a structure. For example, a capstone block 340 may have
a second mating area 347 to mate with a first mating area 46. 146
of an adjacently placed standard block 40 and/or transition block
140, respectively, while also having a transition mating area 360
to mate with a first mating area 46, 146 of an intersectingly
placed standard block 40 and/or transition block 140,
respectively.
[0061] Other embodiments (not shown) may have only a first mating
area 146 on the top of the block 140. That is the bottom of the
block 140 may be substantially planar. Such an embodiment may be
used as a header, or lintel, over a doorway or window opening in
the system 10.
[0062] With continued reference to the drawings, FIGS. 7A-7B depict
an embodiment of standard block 40 having a utility groove 80
located within the block 40. Utility groove 80 may be a channel, a
trough, a path, a vertical cut-out, an opening, and the like. The
utility groove 80 may be any groove, channel, and the like, that
may carry, hold, hoist, suspend, accommodate, etc., a variety of
materials, such as wiring, through the inside of the block 40. The
utility groove 80 may be comprised of three planar surfaces forming
more than one holding areas, wherein the utility groove 80 extends
the horizontal length of the block 40 and/or extends throughout a
single block 40, or a plurality of blocks 40 in system 10.
Alternatively, the utility groove 80 may be a rounded, or
curvilinear, surface forming more than one holding areas, wherein
the utility groove extends the horizontal length of block 40 and/or
extends throughout a single block 40, or a plurality of blocks 40
in system 10. In yet another embodiment, the utility groove 80 may
be comprised of a combination of planar surfaces and curvilinear
surfaces to form a groove extending through a single block 40 or a
plurality of blocks 40. Furthermore, the utility groove 80 may be
coplanar with horizontal surface 49. The holding areas created by
the utility groove 80 may each be coplanar with each other, such
that the bottom surface of the utility groove 80 may be coplanar,
or level, with respect to each other.
[0063] One having skill in the art will appreciate that there may
be more than one utility groove 80 per each block 40. Moreover, a
utility groove 80 located proximate the first mating area 46 may be
aligned with a utility groove 80 of an adjacent block, so as to
allow the utility groove 80 to continue along passing through a
plurality of blocks 40. An installer may then be able to insert a
reinforcing bar, wiring, or any other useful elongate object into a
utility groove 80 located on an exposed block 40, and thread or
slide the bar or wiring through each of the plurality of blocks 40,
without having to disassembly or destroy the existing construction.
Those having skill in the art will appreciate that reinforcing bar,
wiring, or any elongate element may be placed into the utility
groove 80 simultaneous with the construction of system 10, and
exposed utility grooves 80 may provide additional access to
previously placed rebar or wiring. Thus, the utility groove 80, in
particular, the depths of the utility groove 80, may allow a
reinforcing bar, set of wires, or other elongate element or
elements placed within the utility groove 80 located in the block
40 to remain flush with horizontal face 49. The reinforcing bar, or
other elements located within the groove 80 remaining flush with
horizontal surface 49 may allow another block 40, 140, 240, or 340
to be stacked on top of block 40 without affecting its ability to
engage and properly lock with the bottom block 40. Additionally,
the utility groove 80 may be vertically aligned with each other and
share axial communication.
[0064] The utility groove 80 may also be referred to as a plurality
of supports, the plurality of supports located proximate the first
mating area 46. Additionally, the groove 80 may be a series or
plurality of openings located within block 40, wherein the
plurality of openings are coplanar and axially aligned with each
other. The utility groove 80 may also be a uniform opening located
proximate a first mating area 46 extending throughout the block 40,
wherein the uniform opening is separated by at least one vertical
opening, or cavity 45.
[0065] FIGS. 8A-8C depict an embodiment of a transition block 140
having a utility groove 180 located within the block 140. Utility
groove 180 may be a channel, a trough, a path, a vertical cut-out,
an opening, and the like. The utility groove 180 may be any groove,
channel, and the like, that may carry, hold, hoist, suspend,
accommodate, etc., a variety of materials, such as wiring, through
the inside of the block 140. The utility groove 180 may be
comprised of three planar surfaces forming more than one holding
areas, wherein the utility groove 180 extends the horizontal length
of the block 140 and/or extends throughout a single block 140, or a
plurality of blocks 140 in system 100. Alternatively, the utility
groove 180 may be a rounded, or curvilinear, surface forming more
than one holding areas, wherein the utility groove extends the
horizontal length of block 140 and/or extends throughout a single
block 140, or a plurality of blocks 140 in system 100. In yet
another embodiment, the utility groove 180 may be comprised of a
combination of planar surfaces and curvilinear surfaces to form a
groove 180 extending through a single block 140 or a plurality of
blocks 140. Furthermore, the utility groove 180 may be coplanar
with horizontal surface 149. The holding areas created by the
utility groove 180 may each be coplanar with each other, such that
the bottom surface of the utility groove 180 may be coplanar, or
level, with respect to each other. Each block 40, 140 may have at
least one utility groove 80, 180 to facilitate the placement of one
or more construction elements, such as reinforcing bars per each
block 40, 140. One having skill in the art will appreciate that
there may be more than one utility groove 180 per each block
140.
[0066] With reference to FIGS. 9A-9B, a utility groove 180 located
proximate the first mating area 146 may be aligned with a utility
groove 180 of an adjacent block, so as to allow the utility groove
180 to continue along passing through a plurality of blocks 140. An
installer may then be able to insert a reinforcing bar, wiring, or
any other useful elongate object into a utility groove 180 located
on an exposed block 140, and thread or slide the bar or wiring
through each of the plurality of blocks 140, without having to
disassemble or destroy the existing construction. Those having
skill in the art will appreciate that reinforcing bar, wiring, or
any elongate element may be placed into the utility groove 180
simultaneous with the construction of system 100, and exposed
utility grooves 180 may provide additional access to previously
placed rebar or wiring. In addition, the exposed openings of the
utility grooves 80, 180, may allow freshly poured cement into
cavity 45, 145, to weep and relieve pressure created from the
introduction of the flowable, hardenable material 70. Thus, the
utility groove 180, in particular, the depths of the utility groove
180, may allow a reinforcing bar, set of wires, or other elongate
element or elements placed within the utility groove 180 located in
the block 140 to remain flush with horizontal face 149. The
reinforcing bar, or other elements located within the groove 180
remaining flush with horizontal surface 149 may allow another block
40, 140, 240, or 340 to be stacked on top of block 140 without
affecting its ability to engage and properly lock with the bottom
block 140. Additionally, the utility groove 180 may be vertically
aligned with each other and share axial communication. The
embodiment of an assembly of system 100 (shown in FIGS. 9A and 9B)
depicts the alignment of the standard blocks 40, the transition
blocks 140, capstone blocks 340, and their respective utility
grooves 180 when forming a structure or plurality of planar
surfaces.
[0067] The utility groove 180 may also be referred to as a
plurality of supports, the plurality of supports located proximate
the first mating area 146. Additionally, the groove 180 may be a
series or plurality of openings located within block 140, wherein
the plurality of openings are coplanar and axially aligned with
each other. The utility groove 180 may also be a uniform opening
located proximate a first mating area 146 extending throughout the
block 140, wherein the uniform opening is separated by at least one
vertical opening, or cavity 145.
[0068] Referring now to FIGS. 10A-10C, a reinforcing bar or other
suitable reinforcement (not shown) may be located within, threaded
or slid through, or extended through a block 40, 140. For instance,
the block 40, 140 may have a plurality of scallops 30 to support,
house, receive, accommodate, accept, contain, hold, etc., a
reinforcing bar extending through the block 40, 140. Scallops 30
may be a channel, cut-out, openings, extrusions, troughs,
semi-circular hollow tubes, paths, U-shaped channels, and the like.
Moreover, the scallops 30 may have a cross-section, or shape, which
corresponds with the cross-section, or shape, of the reinforcing
bar to be placed within the scallop 30. Each block 40, 140 may have
a plurality of scallops 30 to facilitate the placement of one or
more reinforcing bars per each block 40, 140. In one embodiment, a
block 40, 140 may be configured to have a series of scallops 30,
for example, three scallop sets 32 of two parallel scallops 30 in
series succession. It should be understood that the number of
scallop sets 32 may vary, and in many embodiments, may have at
least one scallop set 32. It should be further understood that
systems 10 and 100 may function using blocks 40, 140 without
scallops 30 or a utility groove 80, 180. Having scallops 30 cut out
or extruded from horizontal face 49 to accommodate a reinforcing
bar or other suitable reinforcement may provide a consistent and
proper alignment through each block 40, 140, and may also increase
the structural strength of the each block 40, 140, in particular,
it may increase the tensile strength of the block 40, 140. Thus,
the overall structural strength of system 10 and system 100 may be
increased, while maintaining the ease and convenience of
installment.
[0069] Moreover, the scallop sets 32 may be in a parallel or a side
by side configuration, and may be spaced apart a horizontal
distance, d.sub.h, across horizontal face 49, as shown in FIG. 10B.
Those with skill in the art will appreciate that distance, d.sub.h,
may vary according to the structural properties and design codes
associated with the particular art. In addition, each scallop set
32 may be spaced apart a distance, d.sub.h, to promote uniformity
and ease of alignment when installing system 10. However, all of
the scallops 30 may be co-planar, for example, the scallops 30 may
share the same plane as horizontal face 49. In other words, the
bottom surface of each scallop 30 may be level, or on the same
plane, with the bottom surface of the other scallops 30 throughout
the block 40, 140 such that a reinforcing bar placed along the
scallops 30 may also be level. Thus, the scallops 30, in
particular, the depths of the scallops 30, may allow a reinforcing
bar placed within the scallops 30 located in the block 40, 140 to
remain flush with horizontal face 49. The reinforcing bar remaining
flush with horizontal surface 49 may allow another block 40, 140 to
be stacked on top of block 40, 140 without affecting its ability to
engage and properly lock with the bottom block 40, 140.
Additionally, the scallops 30 may be vertically aligned with each
other. In other words, the scallops 30 may be axially aligned
throughout the block 40, 140. Axis 32 depicts the vertical or axial
alignment the scallops 30 maintain with respect to each other for
ensuring a properly aligned reinforcing bar within the block 40,
140.
[0070] FIG. 11 shows a close up sectional view of a portion of a
wall installed under the current invention. A footer top 61 has the
strip 20 installed thereon. A first block 40A and second block 40B
are shown on top of each other and on the strip 20, in turn. The
configuration of the second and third planar sections 22A, 22B as
they relate to the configuration of the entire first mating area 46
and the canted surfaces 48A, 48B, are such that upon the
installation of the first block 40A a void space 55 is created
between the bottom of the face 50 and the strip 20.
[0071] Subsequent to the installation of the blocks 40 a flowable,
hardenable material 70 is placed, or pumped, into the openings 45.
The material 70 may be grout, mortar, concrete, epoxy, and the
like. In this manner, a monolithic construct is created between the
block 40, material 70 and the footer 60.
[0072] The material 70 thus can flow within all the openings 45 in
all the blocks 40 as well as into the void 55 around the strip 20.
Thus, the material 70, once hardened, converts the block 40 and
strip 20 construct into a monolithic structure that is strong in
tension, compression, in shear, and the like. The mating areas 46
and 47 add to this aforementioned strength. The strength between
adjacent blocks 40A, 40B is greater.
[0073] The shape of the starter strip 20 and the void 55 it creates
under a first block 40B are such that, once the void 55 is filled
with the flowable, hardenable material 70, and once the material 70
hardens, that the material 70 is prevented from moving in the
vertical direction with respect to the adjacent blocks 40 in the
system 10. That is, the strip 20 and the void 55 together may allow
the material 70 to act as a type of key in the system 10. Therein,
the system 10 is locked to the foundation 60 below.
[0074] As shown in FIG. 11, an optional weep opening 58 may be
located on at least one block 40B so as to allow the escaping off
of trapped air within the openings 45 during the placement of the
material 70. The weep opening(s) 58 may also serve as a viewing
port for quality control purposes, to allow, for example,
construction inspectors to visually confirm that the flowable
material 70 has infiltrated all the openings 45 in the block 40.
The weep opening 58 may be singular, or plural, on each block 40
and may be located in any suitable location on the block 40.
[0075] Clearly, other variations and embodiments are part and
parcel of the invention.
[0076] One such variation is that the foundation 60 can be any
suitable material for placement and support of the system 10. The
foundation 60 is not just limited to concrete footers and the like.
Rather, the term as used herein may include suitably compacted
gravel, soil, and the like. Similarly, the system 10 can be
installed on a foundation 60 constructed specifically for this
application. Contrastingly, the system 10 may bear directly on a
preexisting concrete slab (e.g., slab on grade, elevated slab,
etc.). Thus, the system 10 suits itself for new construction and/or
renovation work; exterior and/or interior partitions; building
construction and/or landscaping/sitework constructs; and, as a
bearing or non-bearing construct. The system 10, for example, can
be used to create interior partitions (e.g., partial height, full
height, etc.) in an existing building to parcel the existing space
into subspaces.
[0077] Another aspect of the invention allows for various materials
to be placed on the exterior of the walls of the system 10. That is
aesthetic; non-structural; and/or, structural materials and/or
systems may be placed on the faces of the blocks 40 once installed.
For example, the system 10 can be covered with paint, covered with
waterproofing, furred out with a wall system, covered with parging,
covered with insulation, or other systems.
[0078] Alternatively, an exterior structural-type parging system 80
(e.g., 1/8'' to 1/4'' thick) may be added that provides a
waterproofing, aesthetic, and/or interlocking strength aspect to
the system 10. One type of system that may be added is an Exterior
Insulation and Finish System (EIFS), such as the system sold under
the name, DRYVIT. Depending on the type of system that is placed on
the exterior of the system 10, flowable, hardenable material 70 may
not necessarily be required to be placed internal to the block 40.
Thus, this exterior system may be used in lieu of, or in addition
to, the flowable, hardenable material 70 placed within the blocks
40. Alternatively yet, a hybrid system may be employed wherein the
exterior parging system is used, while flowable, hardenable
material 70 is only placed in select portions of the system 10. For
example, flowable, hardenable material 70 might only be placed
where structurally necessary, such as in the corners of the
construct and where buttresses, piers, and/or pilasters exist
(i.e., locations of greater stress), while the exterior parging
system is located on the exterior of the blocks 40 throughout.
[0079] While this invention has been described in conjunction with
the specific embodiments outlined above, it is evident that many
alternatives, modifications and variations will be apparent to
those skilled in the art. Accordingly, the embodiments of the
invention as set forth above are intended to be illustrative, not
limiting. Various changes may be made without departing from the
spirit and scope of the invention as defined in the following
claims.
* * * * *