U.S. patent number 3,888,060 [Application Number 05/425,299] was granted by the patent office on 1975-06-10 for construction assembly and method including interlocking blocks.
Invention is credited to Juan Haener.
United States Patent |
3,888,060 |
Haener |
June 10, 1975 |
Construction assembly and method including interlocking blocks
Abstract
Interlocking blocks are assembled in longitudinally staggered
rows. The blocks are planar on their bottom side and include webs
with interlocking protrusions on their upper side. The protrusions
coact with the webs on adjacent rows of blocks to locate and hold
the blocks in position. Corner blocks and end blocks are also
provided so that a series of walls may be constructed without the
need for the usual mortared joints. The protrusions are chamfered
and have associated therewith an excessmaterial-receiving groove to
compensate for manufacturing tolerances. A completed wall may be
grouted through interconnecting cavities in the hollow blocks to
provide additional strength.
Inventors: |
Haener; Juan (San Diego,
CA) |
Family
ID: |
23685959 |
Appl.
No.: |
05/425,299 |
Filed: |
December 17, 1973 |
Current U.S.
Class: |
52/284; 52/503;
52/592.4 |
Current CPC
Class: |
E04B
2/42 (20130101); E04B 2002/0215 (20130101) |
Current International
Class: |
E04B
2/42 (20060101); E04B 2/02 (20060101); E04c
001/08 (); E04c 001/10 (); E04c 001/30 () |
Field of
Search: |
;52/284,286,422,439,437,440,441,503,505,589,593,603,604,605 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
1,000,618 |
|
Oct 1951 |
|
FR |
|
466,776 |
|
Jul 1950 |
|
CA |
|
Primary Examiner: Bell; J. Karl
Attorney, Agent or Firm: Posta, Jr.; John J.
Claims
Having described my invention, I now claim:
1. An interlocking block for use in wall construction assemblies,
which assemblies involve the interlocking of a plurality of
substantially identical blocks to create a substantially continuous
planar wall surface, and wherein said wall construction assemblies
have a plurality of linear courses of blocks, with each said linear
course comprising a plurality of abutting blocks laid end to end,
and wherein the blocks in the courses lying staggered and below any
linear course are in stabgered relationship to the blocks in it's
underlying or overlying linear course, said block comprising:
a pair of spaced parallel side walls having flat upper and lower
faces,
means to maintain said side walls in a spaced relationship,
a plurality of first locking means connected to said side walls,
and disposed between the upper section of said side walls,
said first locking means including a plurality of projections
extending above the upper face of said side walls,
cooperative locking means having cooperating portions connected to
said side walls and disposed between the lower section of said side
walls,
said cooperating locking means terminating at the plane of said
lower face,
the thickness of said projections being less than the thickness of
said cooperating portions,
whereby the projections above the upper face of the side walls on
one block are adapted to cooperate in locking relationship with the
lower cooperating portions of a block placed above said one block
to prevent transverse or longitudinal displacement of the blocks
relative to one another.
2. The interlocking block as set forth in claim 1 wherein each of
said projections include a recessed portion therein.
3. The interlocking block as set forth in claim 2 wherein two
adjacent projections having facing recessed portions.
4. The interlocking block as set forth in claim 3 wherein said
recessed portions comprise substantially right angular notches in
said projections.
5. The interlocking block as set forth in claim 3 wherein the sum
of the distances from the ends of said side walls to the inner side
of the cooperating portions is equal to the distance between the
vertical surfaces of the facing recessed portions.
6. The interlocking block as set forth in claim 3 wherein the sum
of the distances from the ends of the side walls to the vertical
surfaces of the facing recessed portions is equal to the distance
between the inner sides of said cooperating portions.
7. The interlocking block as set forth in claim 3 wherein the sum
of the distances from the ends of the side walls to the inner side
of the cooperating portions is equal to the distance between the
vertical surfaces of the facing recessed portions, and
wherein the sum of the distances from the ends of the side walls to
the vertical surfaces of the facing recessed portions is equal to
the distance between the inner sides of said cooperating
portions,
8. The interlocking block as set forth in claim 4 wherein the
vertical faces of said right angular notch in said projections are
chamfered at an angle to enable ease of assembly of interlocking
blocks.
9. The interlocking block as set forth in claim 4 wherein the lower
horizontal portion of the right angular notch is grooved adjacent
to the vertical face thereof.
10. The interlocking block as set forth in claim 1 wherein said
block includes only three transverse webs.
11. The interlocking block as set forth in claim 3 wherein said
block consists of four symmetrically positioned webs, with the
recessed portions on the inside webs facing each other.
12. The interlocking block as set forth in claim 1 wherein said
means to maintain said side walls in a spaced relationship consists
of a single web.
13. A construction assembly comprising:
a plurality of interlocking blocks,
each of said blocks comprising two substantially planar parallel
side walls, said side walls having upper and lower planar
faces,
a plurality of transverse webs located between said side walls,
each of said webs having protrusions which extend above the upper
planar face of the side walls,
each of said webs having lower cooperating portions integral with
said webs which are entirely located between the side walls above
the lower planar face of the side walls,
said protrusions adapted to cooperate with the lower cooperating
portions of the webs on vertically related blocks,
said protrusions having a smaller thickness than the thickness of
said lower cooperating portions of said webs,
said plurality of blocks being laid up in a plurality of vertically
stacked courses,
said blocks in alternative courses being longitudinally
staggered.
14. The construction assembly as set forth in claim 13 wherein the
lower face of the lower cooperating portions lie in the same plane
as the lower face of the side walls.
15. The construction assembly as set forth in claim 14 wherein the
lower cooperating portions are integral with and essentially the
same thickness as the webs.
16. The construction assembly as set forth in claim 15 wherein said
protrusions are arranged along the upper face of each of said
blocks and are inserted within and engage the lower cooperating
portions of the webs of vertically related blocks above them.
17. The construction assembly as set forth in claim 16 wherein said
protrusions being formed by creating a right angular notch in said
web with only the reduced thickness portion of said web extending
above the upper planar face of said side walls.
18. The construction assembly as set forth in claim 15 and further
including a plurality of corner blocks, said corner blocks
terminating a wall of blocks in a planar finished end and
interlocking said wall with a substantially right angular related
wall.
19. The construction assembly as set forth in claim 17 wherein two
adjacent webs have facing notches.
20. The construction assembly as set forth in claim 19 wherein each
of the outermost of the webs is spaced from the longitudinal end of
said side walls.
21. The construction assembly as set forth in claim 20 wherein the
sum of the distance from the ends of the side walls to the inner
walls of the outermost webs is equal to the distance between the
vertical surfaces of said facing notches.
22. The construction assembly as set forth in claim 20 wherein the
sum of the distance from the ends of the side walls to vertical
surfaces of said facing notches is equal to the distance between
the inner faces of said two adjacent webs.
23. The construction assembly as set forth in claim 15 wherein said
protrusions are formed by creating a substantially right angular
notch in the portion of the web which extends above the upper
planar face of the sides, wherein the vertical face of said notch
is chamfered at an angle.
24. The construction assembly as set forth in claim 23 wherein the
lower horizontal portion of said notch is grooved adjacent to said
vertical face of said notch.
25. The construction assembly as set forth in claim 15 wherein said
block includes at least three transverse webs.
26. The construction assembly as set forth in claim 15 wherein said
block includes four symmetrically positioned webs.
27. The construction assembly as set forth in claim 15 and further
including a plurality of corner blocks terminating the course of
said interlocking blocks and mating said course of interlocking
blocks with a right angularly related course of interlocking
blocks,
said corner blocks being the same length as said interlocking
blocks and including a corner mating means at one end thereof for
locking engagement with a right angularly related corner block.
28. An interlocking block for use in a wall construction assembly,
which assembly is constructed from a plurality of longitudinally
extending, vertically stacked courses of interlocking blocks, with
the blocks in alternate courses being longitudinally displaced,
said interlocking block comprising:
a pair of spaced parallel side walls having flat upper and lower
faces,
a first web extending between said side walls,
a second web extending between said side walls,
the top portion of each web extending above said upper face,
the bottom portion of each web terminating in the same plane as
said lower face,
said top portion having a substantially right angular notch
provided therein,
the thickness of said top portion being smaller than the thickness
of said bottom portion,
the thickness of the bottom portion being essentially the same
thickness as the web,
wherein two adjacent webs have facing notches,
wherein the sum of the distances from the ends of the side walls to
the inner faces of the bottom portion of the outermost webs is
equal to the distance between the vertical surface of said facing
notches,
whereby the top portions of each web in the interlocking block in a
given course are adapted to cooperate in locking relationships with
the bottom portions of the interlocking blocks in the course
immediately above.
29. An interlocking block as set forth in claim 28 wherein there
are only a first and a second web provided, and wherein said block
is symmetrical.
30. An interlocking block as set forth in claim 28 wherein only a
first web, a second web and a third web are provided, and wherein
said block is asymmetrical.
31. An interlocking block as set forth in claim 28 wherein said
block has two inside webs with upper portions having their notches
facing one another,
and wherein said block has two outside webs with upper portions
having their notches facing one another, said block being
symmetrical.
32. An interlocking block as set forth in claim 28 wherein the
horizontal face of the notches is grooved at the vertical face of
the notch.
33. An interlocking block as set forth in claim 28 wherein said
webs include reinforcing bar receiving means for receiving and
locating a receiving bar within the confines of said side
walls.
34. An interlocking block as set forth in claim 33 wherein said
receiving means includes a thin wall knockout portion in said
webs.
35. An interlocking block as set forth in claim 29 wherein the top
portion of the first web on a block in one course is interlocked
with the bottom portion of the second web in the course above.
36. An interlocking block as set forth in claim 28 wherein the top
portion of the outermost webs of abutting blocks in one course is
interlocked with the bottom portion of the webs in course above
which have their top portion notches facing one another.
37. An interlocking block as set forth in claim 28 wherein the
blocks in alternate courses are longitudinally displaced
approximately one-half the length of each block.
38. An interlocking block as set forth in claim 28 wherein the
blocks in alternate courses are longitudinally displaced a distance
other than approximately one-half the length of each block.
Description
BACKGROUND OF THE INVENTION
Concrete block construction is an important factor in the
construction industries of all countries of the world. In many
developing nations a large percentage of substantial structures are
built according to this technique. The existing technique is to
employ concrete blocks which have a plurality of cavities and are
planar on all six sides. The blocks are layed up by placing
concrete mortar by a trowel and then inserting the blocks into the
mortar. Subsequent courses of blocks are layed upon a first course
of blocks after mortar is placed along the side walls of the
supporting blocks and the end walls of the previously layed
blocks.
There is a worldwide shortage of skilled craftsman trained in the
techniques of laying concrete blocks and capable of producing a
wall of a pre-determined height that is true horizontally and
vertically and has the requisite strength. Because of the labor
shortage and the expense of such construction resulting high wages,
concrete block construction has not seen the full utilization it
would otherwise attain.
As a result of the deficiencies of the prior art technique, various
interlocking or mortarless blocks have been proposed. According to
the prevailing theory, interlocking blocks are so constructed that
they may be layed one upon the other, to lay up a wall without the
necessity of skilled tradesmen to align the blocks one upon the
other, to apply the mortar, and to position the blocks
appropriately.
The mortarless or interlocking blocks provided thus far have been
deficient in several respects. The typical prior art interlocking
block is manufactured by the usual moldiing process and then the
various interconnecting grooves and protrusions are formed into the
block by sawing or other forming techniques. Such a block becomes
impractically expensive for most applications.
A further deficiency of prior art interconnecting or mortarless
blocks has been that the interlocking structure has required very
precise molding or other forming so that usual manufacturing
techniques cannot be employed. Thus, the blocks must be made
according to low producing processes which raises the costs beyond
practical limits.
Other prior art techniques have not provided blocks which are
adaptable to use with corner blocks, and end blocks, to accomplish
the intersection and termination of walls without the use of manual
forming and the accompanying skill and labor requirements.
Additionally, some prior art techniques have required that the
blocks be joined by mortar in the conventional fashion and
therefore have been wasteful of material and labor in the joining
operation.
As a result of the deficiencies of prior art mortarless or
interconnecting blocks, these blocks have seen relatively limited
application and the convention prior art technique with its
concomitant high labor and skill requirement is the predominating
usage.
It is therefore desirable to have a mortarless interlocking block
that may be utilized to produce construction assemblies such as
walls and similar structures without the necessity of skilled labor
and wherein the blocks may be produced by conventional techniques
that do not require post-molding forming.
SUMMARY OF THE INVENTION
An exemplary embodiment of the invention incorporates an
interlocking building block having two longitudinal planar upright
side walls, a plurality of transverse spacing webs and interlocking
means protruding from one face of the block. As used herein the
term web should be taken as including a projection extending at
right angles from the interior surface of a side wall. At least one
of the webs must connect between the side walls, but the other webs
in a given block may be partial. The webs have integral protrusions
extending beyond the face of the block and defining interlocking
means in the form of notches in the protrusions. The notches engage
the webs on adjacent blocks to position and hold the blocks. The
inside surfaces of the outermost webs are spaced from the ends of
the side walls by a distance which, in sum, is equal to the
distance between the facing vertical walls of the notches on the
protrusions. The resulting blocks interlock in alternate rows with
a staggered configuration. The block may be assembled with mortar,
mortarless, or with grout or glue as will be described more fully
hereinafter.
An exemplary configuration for the blocks incorporates a symetrical
configuration with four transverse webs. It is to be understood
however, that unsymetrical positioning of the webs and web numbers
in excess of the 2, 3, and 4 web configurations that are
specifically treated hereinafter are equally a part of the
invention. Each web incorporates a protrusion with an interlocking
notch. The notches have vertical faces which open toward the center
of the block. Each interlocking means comprises a right angularly
configured notch in the protrusion of the web beyond the planar
upper face of the block. The substantially vertical wall of the
block is chamfered to produce a wedging action when in cooperative
alignment with the web on the adjacent block. Directly vertically
below the vertical wall of the notch is a material receiving
groove. This groove is for the purpose of receiving material which
is scraped off or otherwise severed from either of the cooperating
surfaces of the interlocking blocks.
In laying up a wall utilizing blocks configured according to the
invention of the first course of blocks is layed with the flat
planar bottom face supported from a concrete floor slab or similar
surface. The blocks are layed end to end with the ends of the side
walls in engagement. The second course of blocks is then placed on
the first course by inserting a block with half of its length
overlapping each of two lower blocks. With this orientation the
inclined surfaces of the interlocking means guide the block as it
is lowered vertically onto the previously layed course. If there is
any out of alignment condition resulting from manufacturing
conditions or other causes, the sloping surfaces will cause a
sufficient amount of material to be removed by abrasion and similar
mechanical action so that the blocks become fully engaged. The
material scraped from either block in the mating action is received
in a groove so that full engagement of the block is accomplished.
As necessary, force is applied to cause the engagement and scraping
action. Where it is desired to provide a sealing and high strength
installation it is desirable to use a concrete cement or thin grout
on the mating surfaces of the blocks prior to the installation
action described above. The grout or glue need not be applied in
the manner of mortar to conventional blocks, but rather merely
serves to seal the joints and secure the interlocked blocks.
Upon completion of a wall of the desired height in the
aforedescribed manner, further strength may be obtained by pouring
grout into the channel created by the hollow cavities formed by the
central cavity and alternately the end cavities in the vertically
related courses of blocks throughout the entire vertical extent of
the wall. The grout, when hardened, creates additional vertical and
horizontal strength for the wall.
Where it is desired to intersect a wall with a right angularly
related wall, or to provide a finished end for a wall combined
corner and end blocks are utilized. The corner blocks have a
configuration according to the interlocking blocks over
approximately one-half of their length and have a corner interlock
configuration over the remainder of their length. The corner
interlock configuration incorporates a substantially square
vertical opening through the end of the block with recesses at
90.degree. increments. A key, positioned to engage the notches on a
cooperating corner block, is located on the upper or lower surface
of each corner block and at the innermost edge of the opening.
At the end of a course of blocks, the corner blocks are used in
conjunction with short end blocks, to produce a finished end for
the wall.
It is therefore an object of the invention to provide a new and
improved construction assembly and method incorporating
interlocking blocks.
It is another object of the invention to provide a new and improved
interlocking block which may be manufactured by conventional
techniques.
It is another object of the invention to provide a new and improved
interlocking block which is relatively low in unit cost.
It is another object of the invention to provide a new and improved
interlocking corner block.
It is another object of the invention to provide a new and improved
interlocking end block.
It is another object of the invention to provide a new and improved
interlocking block which may be assembled by relatively unskilled
labor.
It is another object of the invention to provide a new and improved
interlocking block which may be assembled without mortar.
It is another object of the invention to provide a new and improved
interlocking block with planar surfaces for framing windows and
similar purposes.
It is another object of the invention to provide a new and improved
interlocking block which compensates for manufacturing tolerances
on the interlocking surfaces.
It is another object of the invention to provide a new and improved
interlocking block which may be fully or partially grouted for
increased strength.
It is another object of the invention to provide a new and improved
interlocking block which is susceptable to symetrical and
asymetrical configurations.
It is another object of the invention to provide a new and improved
interlocking block assembly method which reduces construction
time.
Other objects and many attendant advantages of the invention will
become more apparent upon a reading of the following detailed
description, together with the drawing in which like reference
numerals refer to like parts throughout, and in which:
FIG. 1 is a perspective view of a basic four web block.
FIG. 2 is a side elevation view of the block, partially cut
away.
FIG. 3 is a perspective view of a block useable as a corner or end
block.
FIG. 4 is a side elevation view, partially cut away, of the block
of FIG. 3.
FIG. 5 is a perspective view of a short end block.
FIG. 6 is a side elevation view, partially cut away, of the block
of FIG. 5.
FIG. 7 is a perspective view of a typical wall structure using the
three types of blocks.
FIG. 8 is an enlarged sectional view taken on line 8--8 of FIG. 7,
with an inverted finish course of blocks added on top of the
wall.
FIG. 9 and 10 are enlarged sectional views illustrating the
interfitting action of the blocks.
FIG. 11 is a side elevation view, partially cut away, of a two web
form of block.
FIG. 12 is a sectional view of a wall structure using the two web
block.
FIG. 13 is a longitudinal sectional view of a three web block.
FIG. 14 is a sectional view of a wall structure using the three web
block.
FIG. 15 is a perspective view of a first modified form of the block
in a four web configuration.
FIG. 16 is a sectional view taken on line 16--16 of FIG. 15.
FIG. 17 is a perspective view of a second modified form of the
block in a four web configuration.
FIG. 18 is a side elevation view, partially cut away, of the block
in FIG. 17.
FIG. 19 is a longitudinal sectional view of a typical block with
critical dimensions labeled.
FIG. 20 is a perspective view of a third modified form of the block
in a four web configuration.
FIG. 21 is a perspective view of the first modified form of the
block in a two web configuration.
FIG. 22 is a perspective view of a fourth modified form of the
block in a three web configuration.
FIG. 23 is a side elevation view, partially cut away, of the block
made according to a hand molding process.
Referring now to the drawings, there is illustrated three forms of
the interlocking blocks according to the invention. In FIGS. 11 and
12 the form of the block incorporating two transverse webs 12 and
14 is illustrated. The webs interconnect side walls 16. The inner
faces 18 and 20 of the transverse webs 12 and 14 are spaced from
the ends 22 and 24 of the side walls 16 by the same total distance
as separates the substantially vertical faces 26 and 28 of the
interlocking means 30 and 32. Also the faces 26 and 28 of the
interlocking means 30 and 32 are spaced from the respective ends 22
and 24 the same total distance as separates the inner faces 18 and
20.
In a similar manner to that illustrated in FIGS. 11 and 12, an
embodiment of the block according to the invention with three
transverse webs is illustrated in FIGS. 13 and 14. The webs 34 and
36 include facing interlocking means 38 and 40. The third web 42 is
spaced from the end 46 of the side wall 44 and includes
interlocking means 48. The sum of the distances from the ends 46
and 50 of the side walls 44 to the inner edges of the outer webs 42
and 36 is equal to the spacing between the facing vertical faces of
the interlocking means 38 and 40. Further the sum of the distances
from the face 39 to the end 46 and the face 41 to the end 50 is
substantially equal to the spacing between the vertical faces 35
and 37. Thus when these spacing relationships exist, the blocks
will mate and interlock irrespective of the use of three webs and
irrespective of the spacing between webs 34 and 42, so long as the
spacing between webs 34 and 42 are consistant for each block used
and interlocked together. So with this construction, unequal
spacings between the webs and the ends of the blocks can be used
and still obtain the correct interlocking as illustrated in FIGS.
12 and 14.
FIGS. 1, 2, 15 and 17 illustrate several forms of the four web
blocks that will be used for exemplary purposes hereinafter. The
four webs are symetrically oriented. Referring specifically to
FIGS. 1 and 2, inner webs 52 and 54 include facing interlocking
means 56 and 58. The outer webs 60 and 62 include interlocking
means 64 and 66, which also face toward the interior of the block.
The outer webs 60 and 62 are spaced from the ends 68 and 70 of the
side walls 72. The sum of the distances from the ends 68 and 70 to
the inner edges 61 and 63 of the outer webs 60 and 62 is equal to
the spacing between the surfaces 57 and 59 of the substantially
vertical portions of the notches in the interlocking means 56 and
58. Also the sum of the distances between face 65 and end 68 and
between face 67 and end 70 is substantially equal to the spacing
between surfaces 85 and 87. The effect of this spacing relationship
is clearly illustrated in FIG. 8 wherein a plurality of four
symetrically webbed blocks 74 are illustrated in engagement with
one another. It will be noted that the inner webs 52 and 54 have
their interlocking means 56 and 58 in engagement with outer webs 60
and 62 on blocks in the vertically related course of blocks. This
produces engagement of the ends 68 and 70 of the side walls 72.
Similarly, the outer interlocking means 64 and 66 engage the webs
54 and 52 of the vertically related blocks. The size relationship
makes it possible to invert the uppermost course of blocks to
present a planar upper surface as is illustrated.
The upper horizontal exterior edges of the block have horizontal
chamfered edges 140 and the vertical exterior edges have chamfered
edges 142. These chamfered edges enhance the appearance of the
block and form a drip edge to prevent water from entering
joints.
The blocks 74 have two planar side walls which side walls terminate
in planar edges 68, 70 and 84. The webs are coplanar with the
bottom edges 84 and therefore the only portion of the block which
deviates from a planar exterior configuration are the protrusions
of the interlocking means. This configuration for the block makes
it possible for it to be molded in a conventional mold with no
undercuts. It is therefore possible to form all the interlocking
structure and all the other structural features of the block by a
molding process alone.
Referring to FIGS. 3 and 4, the combined end and corner block 88 is
illustrated. Over substantially one half of its length, the corner
block 88 has a configuration identical to that for the block 74.
The remaining portion of the block 88 is configured for terminating
the block at a corner. A hole 90 is substantially rectangular in
configuration and has notches 92, 94 and 96 which receive a tang 98
depending on the orientation of the block at the corner. An end
wall 130 provides a planar flush terminal face.
FIG. 5 illustrates a short end block 100 which is utilized in
conjunction with the corner block 88 to terminate a wall with a
closed planar end. The end block 100 is substantially square being
made up of walls 101, 132, 134 and 136 with wall 101 including a
tang 102. The tang 102 engages the inner face of wall 90 in a
corner block 88.
Referring to FIG. 7 a construction assembly comprising walls 104
and 108 is illustrated. The construction assembly comprises a
plurality of blocks 74 and includes a plurality of corner blocks 88
and short end blocks 100. The tang 98 on the middle combined end
and corner block 88 is received within the recess 92 on the
uppermost combined end and corner block 88.
In the termination of the wall to produce a planar end surface,
corner blocks 88 are utilized in association with short end blocks
100. The tang 102 on the end block 100 is received against the
inner face of wall 90 on the block 88 thus maintaining the
integrity of the interlocked relationship.
In FIGS. 9 and 10, the detailed configuration for the interlocking
means 56 associated with a typical web 52 is illustrated. The
interlocking means 56 comprises a protrusion 110 from the web 52
which extends beyond the planar upper edges of the walls 72. The
protrusion is generally rectangular in configuration and has a
chamfered surface 112 on the substantially vertical wall 114.
Directly below the vertical wall 114 is arranged a material
receiving channel 116. The surface 118 corresponds to the upper
surface of the web 52 and is co-planar with the upper edges of the
walls 72. The relationship between the web 62 of a vertically
related block (not shown) to the interlocking means 56 is
illustrated in the example. The manufacturing tolerances or other
causes have resulted in the slight mis-alignment between the
vertical face 120 on the web 62 and the corresponding vertical face
114 on protrusion 110 of web 52. Thus, in order for the lower
horizontal surface 122 of the web 62 to be forced into engagement
with the corresponding horizontal surface 118 of the web 52, there
must be material removed either from the web 62 or protrusion
110.
In FIG. 9 material is scraped or abraded from the web 62 to produce
a proper fit. The excess material 124 is received in the groove
116, which permits full mating contact between the surfaces 118 and
122. In FIG. 10, the material is removed from the vertical face 114
and deposited in a groove 119. It is to be understood that in some
situations the material may be removed from both the web 62 and the
protrusion 110. In extreme mis-alignments, it is possible that the
entire protrusion 110 will be broken away; however, since there are
four such interlocking devices on each block there will still be
adequate interlocking contact between the vertically related blocks
to maintain them in position.
FIG. 19 represents a generalized configuration for the interlocking
block according to the invention. The following formulas define the
parameters for blocks having one or more webs, which blocks will
interlock with associated blocks as long as the relationships are
maintained:
L = B.sub.1 + B.sub.2 + A.sub.1 + A.sub.2 + C.sub.1 + C.sub.2
C.sub.s = B.sub.1 + B.sub.2
C.sub.c = A.sub.1 + A.sub.2
The length L may alternatively be expressed as:
L.sub.1 = C.sub.s + C.sub.c + C.sub.1 + C.sub.2
In the application of the above formulas to the form of the block
illustrated in FIGS. 13 and 14, it will be seen that the dimension
C.sub.1 is equal to zero, thereby resulting in a single web on the
left half of the block as viewed in that drawing. Similarly for the
two web block such as is illustrated in FIGS. 11 and 12, the
dimensions C.sub.1 and C.sub.2 are both equal to zero.
In symetrical blocks the dimensions A.sub.1 and A.sub.2 are equal,
resulting in a half overlap of blocks in adjacent rows. Thus many
variations are possible from the exemplary configurations
illustrated in the drawings within the limits of the above
formula.
Referring now to FIG. 15, there is illustrated a first modified
form of the interlocking block means according to the invention.
The interlocking means are illustrated in a block having four
complete transverse webs 150, 152, 154 and 156. Each web has
shoulder portions 158 and 160. These shoulders have knock-out
portions 162 and 164, which knock-out portions are separated from
the side walls and main body portion of the webs by grooves 166.
The knock-out portions may be removed by a hammer or similar tool
to make it possible to insert longitudinal reinforcing bars within
the confines of the block. Thus it is possible to meet the
requirements of code for certain installations requiring such
reinforcing.
The protruding portion of the interlocking means such as the
typical protrusion 170 is received between the opposed faces of the
shoulders 158 and 160 on the web of adjacent blocks. Thus, in this
modified form of the invention a centering effect of enhanced
strength is produced.
FIG. 21 illustrates a two web version of the first modified form of
the interlocking block according to FIGS. 15 and 16. A typical web
184 with shoulders 186 and 188 is comparable to the corresponding
web and shoulders illustrated in FIGS. 15 and 16.
A second modified form of the block is illustrated in FIGS. 17 and
18. The block there illustrated is useful in substantially the same
situations as the blocks illustrated in FIGS. 15 and 16; and
differs in that the shoulders, such as typical shoulders 172 and
174, incorporate reinforcing bar receiving recesses 176 and 178. In
those installations requiring reinforcing bars it is only necessary
to break away the thin wall portions 180 and 182 for each of the
bars to provide a longitudinally extending recess along the entire
length of the block.
FIG. 20 illustrates a third modified form of the interlocking block
according to the invention. In this form of the invention partial
webs 190 and 192 are illustrated. The web 190 is typical and is
made up of shoulders 194 and 196 extending from the side walls and
having interlocking means 198 and 200 that cooperate with the inner
faces of webs 202 and 204 on vertically related blocks. In this
block the reinforcing bar receiving provisions need be only in the
webs 202 and 204, since the reinforcing bars may pass by the
shoulders 194 and 196. Accordingly a substantially U-shaped groove
210 is provided on either side of each of the webs 202 and 204. In
this form of the invention it is not necessary to knock out or
otherwise deform the original configuration of the block, in that
the block contains reinforcing provisions in its original
configuration.
Referring now to FIG. 22 a fourth modified form of the interlocking
block according to the invention is illustrated. This block
contains a central enlarged thickness web 220. The central web 220
has no interlocking function and is provided with no interlocking
means. Essentially the block interlocks in the same manner as a two
web block as the two web block illustrated in FIGS. 11 and 12 or in
FIG. 21. The central web 220 serves the purpose of connecting the
two side walls and because of its central location may be used as a
convenient handle for the workman in setting up the block. Then
handle location is advantageous since the block balances about its
center, facilitating the lifting and transportation of the block.
The partial webs 230 and 232 are comprised of a plurality of
shoulders of which shoulder 234 is typical. The inner face 236 of
the shoulder is the working face against which the interlocking
means of the vertically related blocks cooperate. The exterior face
such as the face 238 is not a working surface and therefore may be
faired into the side walls as is illustrated.
Referring now to FIG. 23, there is illustrated the symetrical four
web configuration of the invention which is especially adapted to
hand molding. The webs, such as typical web 240 taper away from the
flat face 242 so that the block may be easily withdrawn from a
mold.
In use, as is illustrated in FIGS. 7 and 8, the blocks are layed
end to end in the desired orientation for the wall or other
structure. The blocks are supported by a concrete slab, footing, or
other suitable planar support (not shown). As required or desired
they may be mortared into position or secured by concrete glue or
grout, such a glue or thin grout serves the purpose of sealing the
block to the associated structure and seals between the several
courses of vertically related blocks. A second course of blocks is
layed upon the first in a longitudinally staggered relationship.
The blocks are inserted so that each block on the second row of
blocks overlies two blocks on the row below. This results in a
contact between the interlocking surfaces on the webs and
protrusions as is illustrated in FIG. 8. If, as will normally be
the case, there is some interference resulting from manufacturing
tolerances between one or more of the webs or protrusions, the
worker will force the block vertically downward causing the webs to
move along the chamfered surfaces and to scrape or abrade off a
sufficient amount of material to allow the blocks to move into edge
to edge contact. The excess material produced by this action will
be received in the grooves 116 and will therefore not build up to a
sufficient degree to prevent full mating of the planar surfaces on
the mating blocks.
At the terminal portions of the wall and around windows and similar
openings the corner block and short end block are utilized to
terminate the wall with a planar face. Similarly at corners of the
wall the corner blocks are utilized with the tangs being received
in the appropriate notches to develop a right angularly related
wall. The blocks 74 for the last course of blocks in a wall are
inverted to produce a planar upper surface for the wall which may
be joined to the roof structure or other mating structure such as
conventional lintels and bond beams.
After the wall has been physically completed in the aforedescribed
manner it may be desirable to insert grout 120 into the channels
interconnecting the various rows of blocks. Such grouting provides
additional horizontal and vertical strength and may be augmented by
the insertion of a reinforcing rod prior to pouring of the grout.
For the four web block 74 it is possible to grout the blocks
through the central cavity and end cavity of alternate rows or
intermediate the outer webs. Grouting intermediate the mating webs
and in the end cavities is illustrated for three web blocks at 120.
The two and three web blocks may be completely filled with grout or
partially grouted as at 120 in FIGS. 12 and 14.
The fully completed wall will be true vertically and horizontally
because of the influence of the interlocking means causing the
worker to obtain proper alignment without elaborate measurement or
other set up. The concrete glue or grout seals between the mating
surfaces to provide a watertight finish, and the chamfered edges of
the block provide a drip edge to prevent the joint adhesive from
being exposed to water flow.
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