U.S. patent application number 13/149189 was filed with the patent office on 2011-12-01 for modular block structures and assemblies thereof.
Invention is credited to Horacio CORREIA.
Application Number | 20110289877 13/149189 |
Document ID | / |
Family ID | 45020932 |
Filed Date | 2011-12-01 |
United States Patent
Application |
20110289877 |
Kind Code |
A1 |
CORREIA; Horacio |
December 1, 2011 |
MODULAR BLOCK STRUCTURES AND ASSEMBLIES THEREOF
Abstract
Modular block structures and assemblies thereof for building
wall facades comprise a plurality of interconnected preformed
blocks with spacers allowing the user to position the modular block
structures in even rows and columns. The modular block structures
include panels with block forms on their front faces. The top and
bottom edges of lower and upper panels in an assembly are
complementarily configured to be mated. The lateral sides of
adjacent panels of an assembly are complementarily configured to be
mated. The modular block structures also include offset ends or
lateral sides.
Inventors: |
CORREIA; Horacio;
(Terrebonne, CA) |
Family ID: |
45020932 |
Appl. No.: |
13/149189 |
Filed: |
May 31, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61349764 |
May 28, 2010 |
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61416962 |
Nov 24, 2010 |
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Current U.S.
Class: |
52/309.4 ;
52/424; 52/561 |
Current CPC
Class: |
E04F 13/147 20130101;
E04F 13/0862 20130101; E04F 13/0851 20130101 |
Class at
Publication: |
52/309.4 ;
52/424; 52/561 |
International
Class: |
E04B 1/04 20060101
E04B001/04; E04C 2/20 20060101 E04C002/20; E04B 1/02 20060101
E04B001/02; E04B 2/02 20060101 E04B002/02 |
Claims
1. A modular block structure for building a wall facade when
assembled on a wall structure in at least one row with similar
modular block structures, said modular block structure comprising:
a panel comprising a front face and a rear side and defining in one
position thereof top and bottom edges and first and second lateral
sides, said rear side providing for being mounted to the wall
structure; and a plurality of blocks formed on said front face,
wherein said first lateral side is complementarily shaped with the
second lateral side of another similar modular block structure and
wherein said second lateral side is complementarily shaped with the
first lateral side of another similar modular block structure.
2. A modular block structure according to claim 1, wherein said
first lateral side comprises a first upper later side portion and a
second lower lateral side portion interconnected by an auxiliary
top edge providing an offset therebetween, said auxiliary top edge
being interconnected said top edge by said first upper later side
portion providing an offset therebetween, said second lateral side
comprising a second upper lateral side portion and a second lower
lateral side portion interconnected by an auxiliary bottom edge
providing an offset therebetween, said auxiliary bottom edge being
interconnected to said bottom edge by said second lower lateral
side portion providing an offset therebetween.
3. A modular block structure according to claim 1, wherein said top
and bottom edges comprises mating elements providing for said top
edge of said modular block structure to mate with the bottom end of
an upper similar modular block structure and providing for said
bottom end of said modular block structure to mate with the top end
of a lower similar modular block structure when assembling said
modular block structure with the similar modular block structure in
a column on the wall structure.
4. A modular block structure according to claim 3, wherein said top
and bottom mating elements comprise respective L-shaped
structures.
5. A modular block structure according to claim 3, wherein one of
said top and bottom mating elements comprises a protrusion and the
other of said top and bottom mating elements comprises an
indentation.
6. A modular block structure according to claim 3, wherein said top
and bottom mating elements comprise respective indentations.
7. A modular block structure according to claim 1, wherein said
panel rear side comprises wall mounting elements.
8. A modular block structure according to any one of claims claim
1, wherein said a plurality of blocks formed on said front face are
spaced apart so as to allow mortar to be filled therebetween.
9. A modular block structure according to claim 1, wherein said
panel front face comprises a space surrounding said plurality of
blocks for being filled with mortar.
10. A modular block structure according to claim 1, wherein said
plurality of blocks are differently configured from one
another.
11. A modular block stricture according to claim 1, wherein said
panel is made of deformable material.
12. A modular block stricture according to claim 1, wherein said
panel comprises urethane foam.
13. A modular block structure according to claim 1, wherein said
panel and said plurality of blocks are formed of the same
material.
14. A modular block structure according to claim 1, wherein said
blocks comprise embossments formed on said panel front face and
covered by a sheet of material.
15. A modular block structure according to claim 14, wherein said
sheet of material comprises cementitious material.
16. (canceled)
17. A modular block assembly for building a wall facade comprising:
a plurality of modular block structures for being assembled in at
least one row on a wall structure, each said modular block
structure comprising a panel comprising front face and a rear side
and defining in one position thereof top and bottom edges and first
and second lateral sides, said rear side providing for being
mounted to the wall structure and a plurality of blocks formed on
said front face, wherein said lateral sides of adjacently assembled
modular block structures are complementarily configured so as to be
mated.
18. A modular block structure for building a wall facade when
assembled with similar modular block structures assembled in at
least one columns on a wall structure, said modular block structure
comprising: a panel comprising a front face and a rear side and
defining in one position thereof top and bottom edges and first and
second lateral sides, said rear side providing for being mounted to
the wall structure; and a plurality of blocks formed on said front
face, wherein said top and bottom edges comprises mating elements
for said top edge of said modular block structure to mate with the
bottom edge of an upper similar modular block structure and
providing for said bottom end of said modular block structure to
mate with the top end of a lower similar modular block
structure.
19. A modular block structure according to claim 18, wherein said
top and bottom mating elements comprise respective L-shaped
structures.
20. A modular block structure according to claim 18, wherein one of
said top and bottom mating elements comprises a protrusion and the
other of said top and bottom mating elements comprises an
indentation.
21. A modular block structure according to claim 18, wherein said
top and bottom mating elements comprise respective
indentations.
22. A modular block structure according to claim 18, wherein said
first lateral side is complementarily shaped with the second
lateral side of another similar modular block structure and wherein
said second lateral side is complementarily shaped with the first
lateral side of another similar modular block structure when
assembling said modular block structure with the similar modular
block structure in a row on the wall structure.
23. A modular block structure according to claim 22, wherein said
first lateral side comprises a first upper later side portion and a
second lower lateral side portion interconnected by an auxiliary
top edge providing an offset therebetween, said auxiliary top edge
being interconnected to said top edge by said first upper later
side portion providing an offset therebetween, said second lateral
side comprising a second upper lateral side portion and a second
lower lateral side portion interconnected by an auxiliary bottom
edge providing an offset therebetween, said auxiliary bottom edge
being interconnected to said bottom edge by said second lower
lateral side portion providing an offset therebetween.
24. (canceled)
25. A modular block structure according to claim 18, wherein said a
plurality of blocks formed on said front face are spaced apart so
as to allow mortar to be filled therebetween.
26. A modular block structure according to claim 18, wherein said
panel front face comprises a space surrounding said plurality of
blocks for being filled with mortar.
27. (canceled)
28. A modular block structure according to claim 18, wherein said
panel is made of deformable material.
29. A modular block stricture according to claim 28, wherein said
panel comprises urethane foam.
30. (canceled)
31. A modular block structure according to claim 18, wherein said
blocks comprise embossments formed on said panel front face and
covered by a sheet of material.
32. A modular block structure according to claim 31, wherein said
sheet of material comprises cementitious material.
33. (canceled)
34. A modular block assembly for building a wall facade comprising:
a plurality of modular block structures of being assembled in at
least one columns on a wall structure, each said modular block
structure comprising a panel comprising a front face and a rear
side and defining in one position thereof top and bottom edges and
first and second lateral sides, said rear side providing for being
mounted to the wall structure, and a plurality of blocks formed on
said front face, wherein said top and bottom edges comprises mating
elements for said top edge of said modular block structure to mate
with the bottom edge of an upper similar modular block structure
and providing for said bottom end of said modular block structure
to mate with the top end of a lower similar modular block
structure.
35. A modular block structure for building a wall facade when
assembled with similar modular block structures on a wall
structure, said modular block structure comprising: a panel
comprising a front face, a rear side for being mounted to the wall
structure, top and bottom edges and first and second lateral sides;
a deformable structure on said front face, wherein said deformable
structure provides for being cut so as to provide block formations
with grooves defined between said block formations.
36-40. (canceled)
41. A modular block assembly for building a wall facade comprising:
a plurality of modular block structures, each said modular block
structure comprising a panel comprising a front face, a rear side,
top and bottom edges and first and second lateral sides and a
deformable structure on said front face, wherein said deformable
structure provides for being cut so as to provide block formations
with grooves defined between said block formations.
42. A modular block structure for building a wall facade when
assembled with similar modular block structures on wall structure,
the modular block structure comprising: a plurality of blocks; a
backing for interconnecting said plurality of blocks; and
peripheral spacers for providing a predetermined space between one
modular block structure and a similar adjacent modular
structure.
43-61. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority on U.S. Provisional
Patent Application Ser. No. 61/349,764 filed on May 28, 2010 and on
U.S. Provisional Patent Application Ser. No. 61/416,962 filed on
Nov. 24, 2010, both of which are incorporated herein by reference
in their entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to blocks and modular blocks
for building facades and building structures such as walls. The
blocks include pre-cast, cement or concrete blocks and like
articles. More specifically, but not exclusively the present
disclosure relates modular block structures and assemblies thereof
for being assembled in rows and columns on a wall structure thereby
providing a wall facade.
BACKGROUND
[0003] Building wall structures using pre-cast blocks is well
known. Many consumers appreciate the look of a wall including
differently sized and shaped blocks. The foregoing gives a wall
structure a more natural look, as if it was built by cut stones
rather than pre-cast blocks.
[0004] Building such structures with pre-cast blocks is very costly
and labor intensive since one would first have to provide various
types of pre-cast blocks greatly increasing production time and
costs. Furthermore, when assembling the blocks, given their varying
dimension, the building process must be well thought out as to make
sure the differently sized and configured blocks can actually be
properly put together like a puzzle to provide for a uniform
wall.
OBJECTS
[0005] It is an object of the present disclosure to provide a
modular block structure.
[0006] It is an object of the present disclosure to provide a
modular bloc assembly.
[0007] It is an object of the present disclosure to provide blocks
with offset ends.
[0008] It is an object of the present disclosure to provide a
modular block facade with offset ends.
[0009] It is an object of the present disclosure to provide a
method of building a structure using blocks.
SUMMARY
[0010] In accordance with an aspect of the disclosure there is
provided a modular block structure for building a wall facade when
assembled on a wall structure in at least one row with similar
modular block structures, the modular block structure comprising: a
panel comprising a front face and a rear side and defining in one
position thereof top and bottom edges and first and second lateral
sides, the rear side providing for being mounted to the wall
structure; and a plurality of blocks formed on the front face,
wherein the first lateral side is complementarily shaped with the
second lateral side of another similar modular block structure and
wherein the second lateral side is complementarily shaped with the
first lateral side of another similar modular block structure.
[0011] In accordance with an aspect of the disclosure, there is
provided a modular block assembly for building a wall facade
comprising: a plurality of modular block structures for being
assembled in at least one row on a wall structure, each modular
block structure comprising a panel comprising front face and a rear
side and defining in one position thereof top and bottom edges and
first and second lateral sides, the rear side providing for being
mounted to the wall structure and a plurality of blocks formed on
the front face, wherein the lateral sides of adjacently assembled
modular block structures are complementarily configured so as to be
mated.
[0012] In accordance with an aspect of the disclosure, there is
provided a modular block structure for building a wall facade when
assembled with similar modular block structures assembled in at
least one columns on a wall structure, the modular block structure
comprising: a panel comprising a front face and a rear side and
defining in one position thereof top and bottom edges and first and
second lateral sides, the rear side providing for being mounted to
the wall structure; and a plurality of blocks formed on the front
face, wherein the top and bottom edges comprises mating elements
for the top edge of the modular block structure to mate with the
bottom edge of an upper similar modular block structure and
providing for the bottom end of the modular block structure to mate
with the top end of a lower similar modular block structure.
[0013] In accordance with an aspect of the present disclosure,
there is provided a modular block assembly for building a wall
facade comprising: a plurality of modular block structures of being
assembled in at least one columns on a wall structure, each modular
block structure comprising a panel comprising a front face and a
rear side and defining in one position thereof top and bottom edges
and first and second lateral sides, the rear side providing for
being mounted to the wall structure, and a plurality of blocks
formed on the front face, wherein the top and bottom edges
comprises mating elements for the top edge of the modular block
structure to mate with the bottom edge of an upper similar modular
block structure and providing for the bottom end of the modular
block structure to mate with the top end of a lower similar modular
block structure.
[0014] In an embodiment, the first lateral side comprises a first
upper later side portion and a second lower lateral side portion
interconnected by an auxiliary top edge providing an offset
therebetween, the auxiliary top edge being interconnected the top
edge by the first upper later side portion providing an offset
therebetween, the second lateral side comprising a second upper
lateral side portion and a second lower lateral side portion
interconnected by an auxiliary bottom edge providing an offset
therebetween, the auxiliary bottom edge being interconnected to the
bottom edge by the second lower lateral side portion providing an
offset therebetween.
[0015] In an embodiment, the top and bottom edges comprises mating
elements providing for the top edge of the modular block structure
to mate with the bottom end of an upper similar modular block
structure and providing for the bottom end of the modular block
structure to mate with the top end of a lower similar modular block
structure when assembling the modular block structure with the
similar modular block structure in a column on the wall structure.
In an embodiment, the top and bottom mating elements comprise
respective L-shaped structures. In an embodiment, one of the top
and bottom mating elements comprises a protrusion and the other of
the top and bottom mating elements comprises an indentation. In an
embodiment, the top and bottom mating elements comprise respective
indentations.
[0016] In an embodiment, the panel rear side comprises wall
mounting elements.
[0017] In an embodiment, the plurality of blocks formed on the
front face are spaced apart so as to allow mortar to be filled
therebetween. In an embodiment, the panel front face comprises a
space surrounding the plurality of blocks for being filled with
mortar. In an embodiment, the plurality of blocks are differently
configured from one another. In an embodiment, the blocks comprise
embossments formed on the panel front face and covered by a sheet
of material. In an embodiment, the sheet of material comprises
cementitious material.
[0018] In an embodiment, the panel is made of deformable material.
In an embodiment, the panel comprises urethane foam. In an
embodiment, panel and the plurality of blocks are formed of the
same material.
[0019] In accordance with an aspect of the disclosure, there is
provided a modular block structure for building a wall facade when
assembled with similar modular block structures on a wall
structure, the modular block structure comprising: a panel
comprising a front face, a rear side for being mounted to the wall
structure, top and bottom edges and first and second lateral sides;
a deformable structure on the front face, wherein the deformable
structure provides for being cut so as to provide block formations
with grooves defined between the block formations.
[0020] In accordance with an aspect of the disclosure, there is
provided a modular block assembly for building a wall facade
comprising: a plurality of modular block structures, each modular
block structure comprising a panel comprising a front face, a rear
side, top and bottom edges and first and second lateral sides and a
deformable structure on the front face, wherein the deformable
structure provides for being cut so as to provide block formations
with grooves defined between the block formations.
[0021] In an embodiment, the first lateral side is complementarily
shaped with the second lateral side of another similar modular
block structure and wherein the second lateral side is
complementarily shaped with the first lateral side of another
similar modular block structure when assembling the modular block
structure with the similar modular block structure in a row on the
wall structure. In an embodiment, the first lateral side comprises
a first upper later side portion and a second lower lateral side
portion interconnected by an auxiliary top edge providing an offset
therebetween, the auxiliary top edge being interconnected to the
top edge by the first upper later side portion providing an offset
therebetween, the second lateral side comprising a second upper
lateral side portion and a second lower lateral side portion
interconnected by an auxiliary bottom edge providing an offset
therebetween, the auxiliary bottom edge being interconnected to the
bottom edge by the second lower lateral side portion providing an
offset therebetween.
[0022] In an embodiment, the top and bottom edges comprise mating
elements providing for the top edge of the modular block structure
to mate with the bottom end of an upper similar modular block
structure and providing for the bottom end of the modular block
structure to mate with the top end of a lower similar modular block
structure when assembling the modular block structure with the
similar modular block structures in a column on the wall
structure.
[0023] In an embodiment, the deformable structure comprises
urethane foam.
[0024] In accordance with an aspect of the disclosure, there is
provided a modular block structure for building a wall facade when
assembled with similar modular block structures on wall structure,
the modular block structure comprising: a plurality of blocks; a
backing for interconnecting the plurality of blocks; and peripheral
spacers for providing a predetermined space between one modular
block structure and a similar adjacent modular structure.
[0025] In accordance with an aspect of the disclosure, there is
provided a modular block structure assembly building a wall facade
comprising: a plurality of modular block structures, each modular
block structure comprising a plurality of blocks; a backing for
interconnecting the plurality of blocks; and peripheral spacers for
providing a predetermined space between one modular block structure
and a similar adjacent modular block structure.
[0026] In accordance with an aspect of the disclosure, there is
provided a modular block structure for building a wall facade when
assembled with similar modular block structures on a wall
structure, the modular block structure comprising: a plurality of
blocks, spacer elements for interconnecting the plurality of
blocks; and peripheral spacers for providing a predetermined space
between one modular block structure and a similar adjacent modular
block structure.
[0027] In accordance with an aspect of the disclosure, there is
provided a modular block structure assembly for building a wall
facade comprising: a plurality of modular block structures, each
modular block structure comprising a plurality of blocks with
spacer elements for interconnecting the plurality of blocks and
peripheral spacers, wherein when assembling the plurality of
modular block structures on a wall structure, the peripheral
spacers provide a predetermined space between two adjacent modular
blocks.
[0028] In an embodiment, the peripheral spacers protrude from the
plurality of blocks.
[0029] In an embodiment, the blocks are differently configured from
one another.
[0030] In accordance with an aspect of the disclosure, there is
provided a modular block structure comprising: a generally
rectangular main body defining in one position thereof main top and
bottom surfaces and main front and rear surfaces, at least one of
the front and rear surfaces defining a modular facade surface, the
modular facade surface comprising at least one elongate groove
defining adjacent block forms; a first end comprising a first upper
lateral side and a first lower lateral side interconnected by an
auxiliary top surface providing an offset therebetween, the
auxiliary top surface being interconnected to the main body top
surface by the first upper later side providing an offset
therebetween; and a second end comprising a second upper lateral
side and a second lower lateral side interconnected by an auxiliary
bottom surface providing an offset therebetween, the auxiliary
bottom surface being interconnected to the main body bottom surface
by the second lower later side providing an offset therebetween,
wherein when assembling a plurality of the modular block
structures, the grooves of the assembled modular block structure
are adapted to be filled with mortar and the first end of one
modular block structures is adapted to mate with the second end of
another adjacent modular block structure.
[0031] In accordance with an aspect of the disclosure, there is
provided a modular block structure assembly comprising: a plurality
of modular block structures, each of modular block structure
comprises a generally rectangular main body defining in one
position thereof main top and bottom surfaces and main front and
rear surfaces, at least one of the front and rear surfaces defining
a modular facade surface, the modular facade surface comprising at
least one elongate groove defining adjacent block forms; a first
end comprising a first upper lateral side and a first lower lateral
side interconnected by an auxiliary top surface providing an offset
therebetween, the auxiliary top surface being interconnected to the
main body top surface by the first upper later side providing an
offset therebetween; and a second end comprising a second upper
lateral side and a second lower lateral side interconnected by an
auxiliary bottom surface providing an offset therebetween, the
auxiliary bottom surface being interconnected to the main body
bottom surface by the second lower later side providing an offset
therebetween, wherein when assembling the plurality of modular
block structures, the grooves of the assembled modular block
structures are adapted to be filled with mortar and the first end
of one modular block structure is adapted to mate with the second
end of another adjacent modular block structure.
[0032] In embodiment, the modular facade comprises at least two
block forms. In an embodiment, at least two block forms are
differently configured.
[0033] In embodiment, each generally rectangular main body is
similarly constructed.
[0034] In embodiment, each main body comprises a motif of the block
forms. In embodiment, each main body comprises a similar motif.
[0035] In accordance with an aspect of the disclosure, there is
provided a building block comprising: a generally rectangular main
body defining in one position thereof main top and bottom surfaces
and main front and rear surfaces; a first end comprising a first
upper lateral side and a first lower lateral side interconnected by
an auxiliary top surface providing an offset therebetween, the
auxiliary top surface being interconnected to the main body top
surface by the first upper later side providing an offset
therebetween; and a second end comprising a second upper lateral
side and a second lower lateral side interconnected by an auxiliary
bottom surface providing an offset therebetween, the auxiliary
bottom surface being interconnected to the main body bottom surface
by the second lower later side providing an offset therebetween,
wherein when interconnecting two like building blocks end to end,
the first end of one building block mates with the second end of
another adjacent building block.
[0036] In accordance with an aspect of the disclosure, there is
provided a building block assembly comprising: a plurality of
building blocks, each building block comprising: a generally
rectangular main body defining in one position thereof main top and
bottom surfaces and main front and rear surfaces; a first end
comprising a first upper lateral side and a first lower lateral
side interconnected by an auxiliary top surface providing an offset
therebetween, the auxiliary top surface being interconnected to the
main body top surface by the first upper later side providing an
offset therebetween; and a second end comprising a second upper
lateral side and a second lower lateral side interconnected by an
auxiliary bottom surface providing an offset therebetween, the
auxiliary bottom surface being interconnected to the main body
bottom surface by the second lower later side providing an offset
therebetween, wherein when interconnecting two like building blocks
end to end, the first end of one building block mates with the
second end of another adjacent building block.
[0037] Other objects, advantages and features of the present
disclosure will become more apparent upon reading of the following
non-restrictive description of illustrative embodiments thereof,
given by way of example only with reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0038] In the appended drawings, where like reference numerals
indicate like elements throughout and where:
[0039] FIG. 1 is front elevational view of a modular block
structure in accordance with a non-restrictive illustrative
embodiment of the present disclosure;
[0040] FIG. 2 is a front view of an modular block assembly
including a plurality of assembled modular block structures in
accordance with a non-restrictive illustrative embodiment of the
present disclosure;
[0041] FIG. 3 is front elevational view of a modular block
structure in accordance with another non-restrictive illustrative
embodiment of the present disclosure;
[0042] FIG. 4 is a front view of an modular block assembly
including a plurality of assembled modular block structures in
accordance with a non-restrictive illustrative embodiment of the
present disclosure;
[0043] FIG. 5 is front perspective view of a modular block
structure in accordance with a further non-restrictive illustrative
embodiment of the present disclosure;
[0044] FIG. 6 is a lateral perspective view of the modular block
structure of FIG. 5;
[0045] FIGS. 7a, 7b and 7c show lateral sectional view of
interconnected upper and lower modular block structures in
accordance with other non-restrictive illustrative embodiments of
the present disclosure;
[0046] FIG. 8 is lateral section view of the top end of modular
block structure with a wall connector in accordance with a
non-restrictive illustrative embodiment of the present
disclosure;
[0047] FIG. 9 is a sectional view of a modular block structure in
accordance with yet another non-restrictive illustrative embodiment
of the present disclosure;
[0048] FIG. 10 is a sectional view of a modular block structure in
accordance with yet a further non-restrictive illustrative
embodiment of the present disclosure;
[0049] FIG. 11 is a front perspective view of a modular block
structure in accordance with still another non-restrictive
illustrative embodiment of the present disclosure;
[0050] FIG. 12 is a rear view of the modular block structure of
FIG. 11;
[0051] FIG. 13 is a perspective view of a pair of building blocks
in accordance with a non-restrictive illustrative embodiment of the
present disclosure being interconnected end to end;
[0052] FIG. 14 is a perspective view of a pair of modular blocks in
accordance with a non-restrictive illustrative embodiment of the
present disclosure being interconnected end to end;
[0053] FIGS. 15-22 are front elevational views of modular blocks in
accordance with non-restrictive illustrative embodiments of the
present disclosure; and
[0054] FIG. 23 is a front elevational view of the modular blocks of
FIGS. 15-22 being assembled to provide a building structure such as
a wall.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0055] Modular block structures and assemblies thereof for building
wall facades comprise a plurality of interconnected preformed
blocks with spacers allowing the user to position the modular block
structures in even rows and columns. The modular block structures
include panels with block forms on their front faces. The top and
bottom edges of lower and upper panels in an assembly are
complementarily configured to be mated. The lateral sides of
adjacent panels of an assembly are complementarily configured to be
mated.
[0056] A modular building block comprises a generally rectangular
main body and first and second ends. The main body defines main
top, bottom, front and rear surfaces. At least one, of the front
and rear surfaces, defines a modular facade surface having grooves
defining block forms. The first end comprises first upper and lower
lateral sides interconnected by an auxiliary top surface providing
an offset therebetween. The auxiliary top surface is interconnected
to the main body top surface by the first upper later side
providing an offset therebetween. The second end comprises second
upper and lower lateral sides interconnected by an auxiliary bottom
surface providing an offset therebetween. The auxiliary bottom
surface is interconnected to the main body bottom surface by the
second lower lateral side providing an offset therebetween. When
assembling like blocks to build a structure, the grooves of the
blocks are adapted to be filled with mortar and the first ends of
the blocks are adapted to mate with the second ends of adjacent
blocks.
[0057] With reference to the Figures non-limiting illustrative
embodiments according to aspects of the disclosure will now be
described.
[0058] FIG. 1 shows a modular block structure 10 comprising three
pre-formed blocks 12 which are interconnected via spacers 14 in the
form of short stems. The modular block structure 10 includes
opposite offset ends 16 and 18 forming L-shaped openings at each
side 16 and 18. As such, the end 16 of one modular structure 10
mates with the end 18 of an adjacent modular structure 10 thereby
providing modular block structure assembly 20 such as that shown in
FIG. 2 when building a wall facade.
[0059] The modular block structures 10 also include outer or
peripheral spacers 22 in the form of tabs in order to assemble
similar modular block structures at predetermined distances
therebetween. The blocks 12 are provided with uneven perimeters 23
in order give the illusion of being cut from stone which are not
suitable for acting as locators in order to properly and easily
assemble structures 10 in vertical and horizontal side by side
rows. The tabs 22 provide the structures 10 with being evenly
assembled which building a wall facade.
[0060] In order to provide a more natural looking wall facade, each
modular block structure can include at least three blocks 12A, 12B,
12C (see FIG. 2) having different lengths and motifs. The random
layout of blocks on a wall can further be provided by using several
different types of modular block structures rather than a single
type of structure having the same block motif. The foregoing is
shown in FIG. 2 for example, where the assembly 20 includes three
similar modular block structures 10 and an additional modular block
structure 11 having a different configuration.
[0061] Once assembled on a wall, the various blocks 12 form spaces
or valleys therebetween which are filled by mortar thereby
completing the wall facade.
[0062] FIG. 3 shows a modular block structure 30 comprising three
blocks 12 which are held together by a backing 32. In essence, the
modular structure 30 is similar to structure 10 except that instead
of spacers 14, it is provided with a backing panel 32. As such, the
modular structure also includes spacer tabs 22.
[0063] FIG. 4 shows assembled modular block structures 30 as well
as additional modular structure 31 providing a modular block
assembly 36 for building a wall facade. As explained in FIG. 2, the
blocks 12 are spaced from each other and these spaces are filled
with mortar in order to complete the wall facade providing it with
a plurality of different and randomly positioned uneven blocks
giving the allure of a wall made by naturally cut stone.
[0064] Turning to FIGS. 5 and 6, a modular block or stone structure
40 is shown comprising panel 42 having offset top and bottom
portions 41 and 43, respectively, and thereby defining a pair of
offset ends 44 and 46. The ends 44 and 46 provide L-shaped openings
48 and 50 for mating with similar modular structures 40. In
essence, the end 46 of one modular structure 40 will mate with the
end 44 of an adjacent modular structure 40.
[0065] The front face 52 of the panel 42 includes a plurality of
block or stone structures 13 which can be provided in a variety of
random formations. The spaces or valleys 54 between the stone
structures 13 can be filled with mortar as previously
explained.
[0066] FIGS. 9 and 10 show respective sectional views of the
modular block structure 40. As shown, the complete structure 40 can
be made out of the same material and comprise a formation on its
front face 52 in order to provide stone facades 13 as shown by
embossments 56. The embossments 56 can be covered by a sheet 58
made of cementitious material, such as concrete material for
example, giving the allure of a stone as shown in FIG. 10.
[0067] The panel 42, itself, can be made from urethane foam or
other suitable and light material. In this way, the module 40 is
itself is provided is light and easy to handle and assemble.
[0068] With respect to FIG. 9, longitudinal elements 60 can be
inserted on the rear side 62 of the modular structure 40, these
longitudinal elements 60 can then be include hooks or other
mounting members including adhesive material for being mounted to a
wall surface. In another embodiment, the longitudinal elements 60
can be used during processing of the structures 40 to be removed so
as to provide a rear opening similar to the one discussed in FIG. 8
below.
[0069] FIGS. 7a to 7c show three respective pair 64, 66 and 68 of
top and bottom modular structures interconnected at their
respective bottom and top ends
[0070] FIG. 7a shows a pair 64 of top and bottom modular structures
70 and 72 respectively. The bottom end 74 of the top modular
structure 70 is interconnected to the top end 76 of the bottom
structure 72. Ends 74 and 76 define mutually complementary L-shaped
structures that are easy to mate during assembly.
[0071] FIG. 7b shows a pair 66 of top and bottom modular structures
78 and 80 respectively. The bottom end 82 of the top modular
structure 78 is interconnected to the top end 84 of the bottom
structure 80. The top end 84 of the bottom structure 80 includes a
protrusion 86 for being received by a complementary indentation 88
formed at the bottom end 82 of the top modular structure 78.
[0072] FIG. 7c shows a pair 68 of top and bottom modular structures
90 and 92 respectively. The bottom end 94 of the top modular
structure 90 is interconnected to the top end 96 of the bottom
structure 94. The ends 94 and 96 include respective interfacing
indentations 98 for creating a latitudinal bore to receive a
connector element 100 therein.
[0073] FIG. 8 shows the top end 102 of a modular structure 104
having an L-shaped top formation 106 for mating with a
complimentarily shaped bottom end of an upper modular structure
(not shown). The inner or rear side 108 of this structure 104
includes an opening 110 for receiving the hook end 112 of an
L-shaped connector 114 which is anchored into a wall via a fastener
116.
[0074] Therefore, the modular structures of the disclosure can be
assembled in horizontal and vertical rows, the side tabs or the
edges of the panel provide for positioning adjacent panels in
horizontal rows, the top and bottom ends provide for mating upper
and lower panels together thereby hiding wall connectors such as
114 behind the assembles panels. The top ends of the uppermost
panels are covered by a longitudinal covering which hides jagged
top ends and which can itself be maked by mortar. The spaces
between stone or block formations are filled with mortar thereby
completing the wall facade.
[0075] The backing panels provided herein can also provide
insulation depending on the material they are made from.
[0076] FIGS. 11 and 12 show a modular structure 120 having an
offset backboard or panel 122 with an offset facade structure 124
on its front face 126. The facade structure 124 can be provided in
foam or other suitable material in order to be randomly cut or cut
according to a pre-defined motif by the user thereby forming block
or stone formations on the front face 126 of the backboard 122.
When a plurality of such modular structures 120 are assembled
together as previously described, then the spaces between the
various stones or blocks can be filled with mortar. The block or
stone forms can also be covered by a thin sheet of concrete in
order to give them a more natural allure.
[0077] As shown in FIG. 12, the rear side 128 comprises a plurality
of mounting elements 130 such as apertures for mounting this
modular structure 120 to a wall.
[0078] FIG. 13 shows a pair of similar building blocks 1010A and
1010B. Each building block 10A or 10B includes a respective
generally rectangular main body 12 having first and second offset
ends 14 and 16 respectively.
[0079] The main body 1012 includes top and bottom surfaces 1018 and
1020 respectively as well as front and rear surfaces 1022 and 1024
respectively. Of course, a surface is defined to be top or bottom
and front or rear depending on how a block 1010A or 1010B is
positioned.
[0080] The first end 1014 includes a first upper lateral side 1026
and a first lower lateral side 1028. Lateral sides 1026 and 1028
are offset in that the upper later side 1026 is positioned inwardly
relative to the lower lateral side 1028. The lateral sides 1026 and
1028 are interconnected by an auxiliary top surface 1030 providing
the offset therebetween. The auxiliary top surface 1030 is
interconnected to the main body top surface 1018 by the first upper
later side 1026 providing an offset therebetween. The auxiliary top
surface 1030 is interconnected to bottom surface 1020 via the lower
lateral side 1028.
[0081] The second end 1016 includes a second upper lateral side
1032 and a second lower lateral side 1034. Lateral sides 1032 and
1034 are offset in that the upper later side 1032 is positioned
outwardly relative to the lower lateral side 1034. The lateral
sides 1032 and 1034 are interconnected by an auxiliary bottom
surface 1036 providing the offset therebetween. The auxiliary
bottom surface 1036 is interconnected to the main body bottom
surface 1020 by the second lower later side 1034 providing an
offset therebetween. The auxiliary bottom surface 1036 is
interconnected to bottom surface 1020 via the lower lateral side
1034.
[0082] In this way, each block 1010A and 1010B includes upper and
lower offset body portions 1011 and 1013 respectively (see FIG.
14). Upper body portion 1011 is defined between lateral sides 1026
and 1032 and lower body portion 1013 is defined between lateral
sides 1028 and 1034. With respect to FIG. 15, the upper and lower
body portions can be differently sized, in this example, the upper
portion 1011 is larger than the lower portion 1013.
[0083] The blocks 1010A and 1010B can be positioned end to end,
with the first end 1014 of one of blocks 1010A or 1010B mating with
the second end 16 of the other of blocks 1010A or 1010B.
[0084] As shown in FIG. 13, the auxiliary top surface 1030 of the
first end 1014 of a block 1010B received thereon the auxiliary
bottom surface 1036 of the second end 1016 of the adjacent block
1010A. In this example, the rear surface 1024 of block 1010A is
abutting the first lateral side 1026 of block 1010B thereby
providing a right angle between the blocks 1010A and 1010B for
building corners.
[0085] In another example, when the blocks are adjoined end to end,
the bottom surface 1036 of the block 1010A is supported by the top
surface 36 of the block 1010B with the lateral side 1032 of block
1010A abutting the lateral side 1026 of block 1010B and thereby
forming a wail structure therewith.
[0086] FIG. 14 shows a pair of blocks 1010C and 1010D which are
similar in construction with previously described blocks 10A and
10B except that the former include grooves 1038 which define block
facade forms 1040. The grooves 1038 can be vertical 1038V (see FIG.
16) or horizontal 1038H (see FIG. 16) and be defined on any surface
of the blocks described herein such as the front and rear surfaces
1022 and 1024 and the lateral sides 1026, 1028, 1032 and 1034
thereby defining a facade surface which provide block forms
1040.
[0087] FIGS. 15-22 respectively show blocks 1010E, 1010F, 1010G,
1010H, 1010I, 1010J, 1010K and 1010L which are all similarly
constructed with varying groove motifs 1042 (see FIGS. 17 and 18)
which define different types of blocks forms 1040. In this way each
block provides a block form layout or motif 1044 (see FIG. 19). The
layout or motif of a given block facade surface includes
differently sized block forms, some being larger while other
longer. Of course, the skilled artisan can easily design different
layouts of motifs 1044 of block forms 1040 depending on where the
grooves 1038 will be made.
[0088] The blocks 1010E, 1010F, 1010G, 1010H, 1010I, 1010J, 1010K
and 1010L are shown to have similar configurations but they may
include similar or different sizes. For example, the blocks 1010E,
1010F and 1010K have a similar groove and block form motifs
1042/1044 with the block 1010G, 1010H and 1010L respectively but
not the same size.
[0089] FIG. 23 shows that when stacking the blocks described herein
and connecting them end to end in order to build a wall structure
W, the various groove motifs 1042 and block form motifs 1044
defined by the blocks forms 1040 and grooves 1038 provide a wall
facade 1046. This wall facade 1046 is further defined when filling
the grooves 1038 with mortar giving the impression that each block
form 1040 is in fact an independent pre-cast connected to other
precast blocks.
[0090] In this way, the blocks 1010E, 1010F, 1010G, 1010H, 1010I,
1010J, 1010K and 1010L act as modular building blocks providing
with only a limited number of groove and block form motifs
1042/1044 provides a large variety of wall facades 46 since it
avoids repeating a given block form layout.
[0091] The foregoing provides for building a plurality of pre-cast
blocks having the same shape and size, thereby making production
relatively cheaper and easier than building differently sized and
configured building blocks. The offset ends of the blocks allow for
mating the blocks end to end when creating a horizontal row, their
similar lengths allows for creating columns by stacking one row
above the next. Providing different groove and block form motifs on
the facade surfaces of the blocks and randomly placing the pre-cast
blocks avoids repeating blocks layout patterns and greatly
increases the chances of producing a wall structure that gives the
impression of having been build with separate differently shaped
and sized blocks (i.e. the block forms) and without redundancy in
the sequence of block layout.
[0092] It is to be understood that the disclosure is not limited in
its application to the details of construction and parts
illustrated in the accompanying drawings and described hereinabove.
The disclosure is capable of other embodiments and of being
practiced in various ways. It is also to be understood that the
phraseology or terminology used herein is for the purpose of
description and not limitation.
[0093] Hence, although the present disclosure has been described
hereinabove by way of embodiments thereof, it can be modified,
without departing from the spirit, scope and nature of the subject
disclosure as defined herein.
* * * * *