Patent Application
20210054623
Conventional concrete masonry block construction typically uses rectangular blocks. To construct a wall, a layer of mortar is applied onto a foundation, and a course of closely spaced blocks are laid on the layer, with additional mortar applied between the contiguous block ends. Another layer of mortar is applied to the top of the first course, and additional courses are similarly laid, generally staggering the block ends from course to course. This method of constructing a wall requires a high level of skill to perform, and costs are often high. While some techniques have been proposed to construct a wall with an assembly of blocks without prepared mortar beds, it can be difficult to ensure adequate insulation and structural support for the wall using these techniques.
One general aspect includes a block for use in mortarless wall construction. The block also includes a top surface and a bottom surface that are parallel to one another. The block also includes a projection that protrudes beyond the top surface along a first axis and is symmetrical along a second axis and a third axis. The block also includes a recess that extends into the bottom surface along the first axis and also is symmetrical along the second axis and the third axis. The block also includes a pair of sidewalls including a first sidewall and a second sidewall that are parallel to one another, where the pair of sidewalls are connected by the top surface and bottom surface, where the pair of sidewalls have end edges generally perpendicular to the top surface and the bottom surface, and where the pair of sidewalls respectively have a first length. The block also includes a pair of endwalls including a first endwall and a second endwall that are parallel to one another, where the pair of endwalls are connected by the top surface and the bottom surface, where the pair of endwalls are transverse and joined to the pair of sidewalls, and where the pair of endwalls respectively have a second length that is substantially half the first length. The block also includes a first trench that is defined by a second recess extending into the first endwall, where the first trench runs along the first axis from a surface of the projection to a surface of the recess, and where a first width of the first trench is defined by a start point and an end point along the third axis. The block also includes a second trench that is defined by a second recess extending into the second endwall, where the second trench runs from a surface of the projection to the surface of the recess, and where a second width of the second trench is defined by a start point and end point along the third axis, where the start point of the second width exists between the start point and the end point of the first width along the third axis. The block also includes a void that is defined in part by a passage through the block that runs from a surface of the projection to a surface of the recess along the first axis, where the void exists between the first trench and the second trench along the second axis, where a third width of the void is defined by a start point and an end point along the third axis, and where the start point of the third width exists between respective endpoints of the first width and the second width so that the third width overlaps with both the first width and the second width along the third axis.
One general aspect includes a block. The block also includes a top surface and a bottom surface that are parallel to one another. The block also includes a projection that protrudes beyond the top surface along a first axis. The block also includes a recess that extends into the bottom surface along the first axis. The block also includes a pair of sidewalls including a first sidewall and a second sidewall that are parallel to one another, where the pair of sidewalls are connected by the top surface and bottom surface, and where the pair of sidewalls have end edges generally perpendicular to the top surface and the bottom surface. The block also includes a pair of endwalls including a first endwall and a second endwall that are parallel to one another, where the pair of endwalls are connected by the top surface and the bottom surface, and where the pair of endwalls are transverse and joined to the pair of sidewalls. The block also includes a first trench that is defined by a second recess extending into the first endwall, where the first trench runs along the first axis from a surface of the projection to a surface of the recess, and where a first width of the first trench is defined by a start point and an end point along a second axis. The block also includes a second trench that is defined by a second recess extending into the second endwall, where the second trench runs from a surface of the projection to the surface of the recess, and where a second width of the second trench is defined by a start point and end point along the second axis, where the start point of the second width exists between the start point and the end point of the first width along the second axis. The block also includes a void that is defined in part by a passage through the block that runs from a surface of the projection to a surface of the recess along the first axis, where the void exists between the first trench and the second trench along a third axis, where a third width of the void is defined by a start point and an end point along the second axis, and where the start point of the third width exists between respective endpoints of the first width and the second width so that the third width overlaps with both the first width and the second width along the second axis.
One general aspect includes a block. The block also includes a top surface and a bottom surface that are parallel to one another. The block also includes a projection that protrudes beyond the top surface along a first axis and is symmetrical along a second axis and a third axis. The block also includes a recess that extends into the bottom surface along the first axis and also is symmetrical along the second axis and the third axis. The block also includes a pair of sidewalls including a first sidewall and a second sidewall that are parallel to one another, where the pair of sidewalls are connected by the top surface and bottom surface, where the pair of sidewalls have end edges generally perpendicular to the top surface and the bottom surface, and where the pair of sidewalls respectively have a first length. The block also includes a pair of endwalls including a first endwall and a second endwall that are parallel to one another, where the pair of endwalls are connected by the top surface and the bottom surface, where the pair of endwalls are transverse and joined to the pair of sidewalls, and where the pair of endwalls respectively have a second length that is substantially half the first length. The block also includes a pair of trenches including a first trench and a second trench that are respectively defined by a recess extending into an endwall of the pair of endwalls, where the pair of trenches both run along the first axis from a surface of the projection to a surface of the recess, and where a first width of the first trench overlaps with a second width of the second trench along the third axis.
In the following description, various examples will be described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the examples. However, it will also be apparent to one skilled in the art that the examples may be practiced without the specific details. Furthermore, well-known features may be omitted or simplified in order not to obscure the example being described.
Embodiments of the present disclosure provide one or more block configurations for respective block types that are utilizable for assembly in a building block system. In one example, a block configuration may specify one or more interconnecting features of a block, whereby the interconnecting features enable the block to be used for more efficient construction a building block system (e.g., a mortarless wall assembly) than conventional methods. In some embodiments, an interconnecting feature of a block may correspond to any feature of the block that enables the block to be interconnected with another block of a same or different block type. In an example, an interconnecting feature may correspond to a projection and/or recess of a block that enables the block to “fit” (e.g., mate, or otherwise lock) together with another block, so as to restrict substantial movement of the blocks relative to each other (e.g., restricting relative movement to a fraction (e.g., 1/16) of an inch). In another example, an interconnecting feature may correspond to a trench and/or void of the block. When a projection of the block is mated with a recess of another block, a trench and/or void of the block may be positionally and dimensionally aligned with a trench and/or void of another block, so as to form a continuous passage between the two blocks. The continuous passage may be configured to receive concrete materials (e.g., cementitious grout, reinforcing rods, etc.) that lock the blocks into permanent positions. In at least this way, a trench and/or void of a block may also facilitate interconnection with other blocks within the block assembly.
Upon completion of mating multiple blocks together to create a stacked block assembly (e.g., a wall assembly) that includes multiple continuous passages, each of these continuous passages may be extended from a lower portion (e.g., a base surface) to an upper portion (e.g., a top surface) of the wall assembly. As described above, the continuous passages may subsequently receive concrete materials that further lock the blocks of the wall assembly into permanent positions and provide insulation support. In at least this way, and, continuing with the mortarless wall assembly example, the interconnecting features the blocks may enable the mortarless wall assembly to be constructed without prepared mortar beds at the seat and head joints of the blocks during an initial erection of the wall assembly. The interconnecting features of the blocks may also enable an efficient mechanism for fixing components into place after the wall erection, and for efficiently insulating the wall to protect against various elements (e.g., fire penetration, water migration, insect migration, and other natural element migrations).
As described above, in some embodiments, a plurality of block types may exist. Depending on a position of a particular block relative to other blocks of a particular building block system (e.g., a wall assembly), a particular block type may be used for the particular block at that position. For example, one type of block may be a “full-length” block, while another type of block may be a “half-length” block. In some embodiments, the full-length block may be substantially twice the length of the half-length block. In some embodiments, the full-length block may contain a plurality (e.g., two, four, etc.) of projections and a corresponding plurality of recesses. In some embodiments, the projections and recesses may be respectively connected together at an interconnection location. For example, in one embodiment, a full-length block may include two cross-shaped (e.g., cross-keyed) projections that interconnect (e.g., and respectively protrude beyond a top surface), and two cross-shaped recesses on a bottom surface that also interconnect (e.g., and respectively extend into the bottom surface). In this embodiment, the corresponding half-length block may include only one cross-shaped projection. As described further herein, the full-length block may also differ from the half-length block in terms of the type and/or number of other interconnecting features.
Within both the half-length and full-length block type categories, respectively, there may be at least four different sub-types of blocks: (1) a standard block that includes at least one projection that protrudes beyond a top surface of the block, and at least one recess that extends into a bottom surface of the block, (2) a flat-top block with a recessed bottom, (3) a U-shaped block having a U-shaped contour with a recessed bottom, and (4) a flat-bottom block with a projection that protrudes beyond the top surface of the block. It should be understood that any suitable type of block and/or arrangement of block types may be utilized to perform embodiments of the present disclosure.
As described above, a block of a particular type may interconnect with one or more other blocks (e.g., of a same or different type) within a particular building block system based on one or more interconnecting features of each block type. The type of interconnection may depend in part on the requirements of the particular building block system. For example, consider a horizontally stacked assembly that runs linearly (e.g., as a wall assembly). A base course of the wall assembly may correspond to a horizontal layer of flat-bottom blocks. Above the base course of flat-bottom blocks, a second course (e.g., an intermediate course) of standard blocks may be horizontally stacked (e.g., mated) with the base course, whereby projections that protrude from the flat-bottom blocks interconnect with recesses extending into bottom surfaces of the standard blocks. A series of intermediate courses (e.g., a third course, a fourth course, etc.) may be stacked similarly to the second course, using the standard type of block. In some embodiments, at the top of the wall assembly, a top course of flat-top blocks with recessed bottoms may be interconnected with projections of an intermediate course of blocks (e.g., the highest intermediate course before reaching the top course). In some embodiments, the top course of flat-top blocks allows for a uniform flat surface on which to place a structural cast-in-place beam (e.g., a concrete beam, or a beam including other materials). In some embodiments, at the top of the wall assembly, instead of flat-top blocks, a top course of U-shaped blocks with recessed bottoms may be used. The top cavity of the U-shaped blocks may receive cast-in-place concrete materials and/or reinforcements, thereby enabling a structural cast-in-place bond beam to be formed, as described further herein.
In some embodiments, the courses of the wall assembly may be placed in a running bond method of placement, whereby individual blocks in a course of blocks overlap with individual blocks that are adjacent (e.g., in another course of blocks above and/or below the course of blocks). For example, an endwall of a particular block in an intermediate course may interconnect with a lower block (e.g., of another lower intermediate course) at the midpoint of the lower block (e.g., half the length of the lower block). In this example, a half-length block of each type (e.g., one of the four sub-types described above) may be placed as an end block (and/or intermediate block) of one or more courses, thereby enabling the running bond placement method from the base to the top of the wall assembly.
In another embodiment, a building block system may include a wall intersection, whereby two linearly stacked assemblies (e.g., two wall assemblies) connect (e.g., at a ninety degree intersection). As described further herein, interconnecting features of one or more of the block types may further allow courses of blocks to interconnect at the wall intersection. For example, in some embodiments, a first standard block may include two cross-shaped projections and two corresponding cross-shaped recesses, as described above. A first cross-shaped recess of the first standard block may be mated with a cross-shaped projection of a second standard block (of the same type as the first standard block), whereby the first standard block is transversely stacked on top of the second standard block at the wall intersection. A second cross-shaped recess of the first standard block may also be mated with a cross-shaped projection of a third standard block that is part of the same linearly stacked assembly as the first standard block. Note that, in this example, blocks of the same type (or different type) may be interconnected in either a linearly stacked assembly (e.g., components of a linear wall) or a transversely stacked assembly (e.g., at a ninety degree wall intersection), depending on the blocks' positions within the building block system. In some embodiments, this interconnective capacity of the blocks (e.g., enabling the block to interconnect at ninety degree turns as well as in a linear interconnection) may be enabled based in part on the projections and recesses of the block, respectively, being symmetrical along both a first axis and a second axis (e.g., being symmetrical in four quadrants of a two-dimensional plane that is parallel to the ground).
In yet another embodiment, a double wall assembly may be formed, for example, by placing two courses of blocks (e.g., standard blocks) adjacent to each other. Above the adjacent courses, standard blocks may be placed above and transverse to the lower blocks, whereby the lower courses of blocks interconnect with the upper blocks based in part on the interconnecting features. It should be understood that any suitable arrangement of building block system may be assembled by utilizing block configurations of blocks of the present disclosure.
In some embodiments, and, as described further herein, upon an initial erection of a building block system (e.g., a wall assembly of a building), the building block system may be further reinforced and/or protected (e.g., insulated) from elements (e.g., fire, water, heat, etc.) based in part on the interconnecting features of the blocks of the building block system. For example, in a case where the blocks are masonry blocks, head joints (e.g., a joints between the ends of masonry blocks) may be sealed based on trenches of adjacent endwalls of the respective blocks being aligned to form a void. For example, in a case where a trench corresponds to a half cylindrically-shaped recess extending into an endwall of a block, the two trenches of adjacent endwalls of respectively adjacent blocks may be aligned to form a full cylindrically shaped void. When the full cylindrically shaped void is aligned with a void of another block stacked above or below the respectively adjacent blocks (e.g., and similarly, with respect to other stacked blocks of the wall), a continuous passage may be formed from the bottom of the wall to the top of the wall. When the continuous passage receives (e.g., is filled with) sealing material (e.g., cementitious grout), gaps between the blocks may be sealed. This sealing may protect the building block system from the elements, while also fixing the blocks into place to prevent relative movement of the blocks. It should be understood that any type and/or number of suitable passages may be created based on interconnecting features of blocks described herein. For example, in one embodiment, at least two types of passages may exist throughout the building block system. As described above, one passage type (e.g., which may be referred to as a “head joint columnar void” or “head joint full columnar void”) may receive cementitious grout, and may primarily serve to insulate the blocks from outside elements and to permanently fix the blocks in place.
Another passage type (e.g., which may be referred to as a “core columnar void”) may also be created based on interconnecting features of one or more block types. The core columnar void may receive cast-in-place cement grout as well as reinforcing rods. In one embodiment, the reinforced concrete void fill may create a concrete column (e.g., within the core columnar void) that extends from the bottom of the wall to a bond beam at the top of the wall. In this way, the concrete column may enable the wall to be capable of bearing structural loads. In some embodiments, a cast-in-place concrete beam is placed at the top of the wall assembly and is connected to the wall by reinforcing rods extending out of the grout-filled core columnar voids into the cast-in-place bond beam plane. In some embodiments, a wall may be further reinforced by using surface bonding cement that is applied at the exterior surfaces of the wall to add horizontal reinforcing to the wall assembly in the form of a planar membrane coating. This surface bonding cement may further protect the wall fabric from exposure to natural environmental elements.
In some embodiments, a block may be formed using any suitable material and/or method. For example, in one embodiment, the block may be made of cementitious material such as cellular lightweight concrete (CLC). The cellular lightweight concrete may be made from one or more types of material, including, but not limited to: lightweight aggregates, such as perlite, pumice, plastics, or pre-formed temporary foam bubbles made from protein emulsions or other synthetic foam agents. In some embodiments, the blocks may be made from pour casting a cementitious material into special form shapes or mold shapes. These shapes may impart distinct features onto and into the cementitious fabric that, when cured, maintain a permanent shape. In some embodiments, the cellular lightweight concrete material may be used based in part on the lightweight properties of the concrete and a selection of a low-strength cured concrete material. The low compressive strength may enable localized yielding of the material fabric when encountering an incursion (such as a gravel or irregularity in the block horizontal bed joint). For example, the block material fabric may deform at an immediate incursion point and absorb or subsume an incursion element (e.g., a gravel) into the block fabric without impairing the structural integrity of the block itself or the overall system. Accordingly, a block formed from cellular lightweight material may contrast with some concrete blocks that may otherwise break at a point of incursion (e.g., a teeter point) when under a gravity load. It should be understood that cellular lightweight concrete corresponds to an example type of material that may be used to perform embodiments. However, embodiments of the present disclosure may be performed using any suitable material (e.g., non-hydraulic cement, hydraulic cement, etc.).
Embodiments of the present disclosure provide several advantages over some methods of assembling a building block system. For example, in the case of some concrete masonry types of block systems, these block systems typically require the blocks to be laid in a prepared horizontal bed of mortar to bond individual courses together. A vertical bed of mortar is also used to connect individual blocks within a horizontal course together at the time the blocks are being installed. This method of installation requires significant skill and labor time to prepare and install mortar materials. In contrast, embodiments of the present disclosure enable blocks to be assembled without prepared mortar beds at the seat and head joints of blocks during the initial erection. This is possible at least in part because of the interconnecting features of the blocks, which enable the blocks to be interconnected (e.g., mated) without pre-preparing the mortar beds. Accordingly, this block system may be more efficiently assembled without requiring as much skill or labor efforts as conventional methods. Also, as described herein, the interconnecting features enable blocks to be interconnected so as to realize both linear interconnectivity and transverse interconnectivity. For example, a standard block may be used to linearly interconnect with one or more other blocks in a linearly stacked assembly. In this example, the same standard block may also be used to transversely interconnect with one or more other blocks in a transversely stacked assembly (e.g., at a ninety degree wall intersection). This may be possible at least because the respective projections and recesses of the standard block are symmetric along any two axes (e.g., in four quadrants) of a plane (e.g., parallel to the ground).
Additionally, as described herein, the interconnecting features may also enable blocks of a building block assembly to be efficiently sealed and firmly (e.g., permanently) locked in place. For example, following the assembly of interconnecting blocks to form wall assembly, block void cavities (e.g., core columnar voids, head joint columnar voids) may be efficiently filled with cementitious material and/or reinforcing rods, depending on the type and/or location of the voids. Accordingly, the filled cavities may permanently fix block components in position and close migratory paths for fire penetration, water migration, insect migration, and other natural element migrations.
Turning now to the figures, the diagram 100 of
Similar to the first isometric view 100A, the second isometric view 100B also illustrates sides of the same standard block. In the second isometric view 1006, three visible sides of the standard block are illustrated: the second endwall 108, the second sidewall 104, and the top surface 102. Note that both isometric views 100A and 1006 provide two different visible views of the second endwall 108 and the first sidewall 110. Also, three non-visible sides of the second isometric view 1006 include: the first endwall 106, the second sidewall 104, and the bottom surface 112.
For clarity of illustration, embodiments of different block types of the present disclosure may be described in reference to one or more axes (an X-axis, a Y-axis, and a Z-axis) of a three-dimensional space 156 (e.g., in the real world). For example, in the diagram 100 of
Turning to the different sides of the block in further detail, in some embodiments, at least one recess may extend into the bottom surface 112. For example, two recesses are illustrated in the first isometric view 100A as extending into the bottom surface 112. In the first isometric view 100A, each recess corresponds to a cross-shaped recess, including both a first cross-shaped recess 116 and a second cross-shaped recess 117. In some embodiments, a shape of the recess (e.g., a cross shape, a square shape, or other suitable polygonal shape) may be symmetrical along two axes (e.g., within a three-dimensional space) so that a portion of the shape (e.g., the keyway array dimensions) in one quadrant of the of the two axes is symmetrical to respective portions of the shape in the other three quadrants. Using the example three-dimensional space 156 described above (e.g., with respect to the second isometric view 1006 of the block), the first cross-shaped recess 116 may extend into the bottom surface 112 along the first axis 150, and may also be symmetrical along the second axis 152 and the third axis 154. In this way, the same block may support realization of both linear interconnectivity and transverse interconnectivity. For example, in one embodiment the first cross-shaped recess 116 may linearly interconnect (e.g., mate) with a lower block in a horizontally stacked assembly (e.g., a wall), as described further below with respect to
In some embodiments, at least one projection may protrude beyond the top surface 102. For example, two projections are illustrated in the second isometric view 1006 of the standard block of
It should be understood that any suitable number of projections and corresponding recesses may exist for a particular block type. For example, a single projection and a single corresponding recess may exist for a particular block type (e.g., a full-length block type, a half-length block type, and/or associated sub-types. For example, in a case of a standard full-length block (e.g., whereby the length of the block along the second axis 152 is twice the width along the third axis 154), less than two (e.g., one) projection/recess pairs may exist (e.g., corresponding to the first cross-shaped recess 116 and the first cross-shaped projection 114). In this example, a particular set of scenarios may be enabled. For example, instead of overlapping the blocks in adjoining courses in a running bond pattern, blocks may be stacked directly on top of each other (e.g., in a wall assembly). In another case of a standard full-length block, more than two (e.g., four, eight, etc.) projections may protrude beyond the top surface, with a matching (e.g., same) number and corresponding placement of recesses. In some embodiments, the number and/or placement of projections and recesses may be chosen so that each projection and corresponding recess is symmetrical in four quadrants of a two-dimensional plane (e.g., along the second axis 152 and the third axis 154).
As described above, in some embodiments, the standard block type illustrated by diagram 100 in
In some embodiments, the standard block (and/or other block types) may include at least two trenches. In some embodiments, a trench may correspond to a recess that extends into an endwall. For example, as depicted in both isometric views of
In some embodiments, the block may include one or more voids, as depicted in diagram 100. In some embodiments, a void may be defined in part by a passage through the block that runs from a surface of a portion of the block to another surface of another portion of the block. For example, as depicted in
As described further herein, when endwalls of two blocks (e.g., of the same or different types) are placed adjacent to each other, the respective trenches of the adjacent endwalls may be aligned such that the two trenches form a second void. In some embodiments, the second void (e.g., formed by aligning the two head joint half voids of adjacent blocks) may have similar (e.g., the same) dimensions as the void 118. For example, as depicted in
As described above, in some embodiments, the block may include more than one void. For example, as depicted in
It should be understood that, although the voids described herein may correspond to cylindrically-shaped voids, embodiments should not be construed to be so limiting. For example, a square shaped void may be used to perform embodiments described herein, for example, whereby the void 118, the second void 122, and/or the third void 124 are square shaped voids. In some embodiments, the shape of the void 118 (e.g., the head joint full columnar void) may be the same or different from the shape of the void 122 and/or 124 (e.g., the core columnar voids), or any suitable combination thereof. In some embodiments, the shape of the void 118 may match the shape of the trenches (e.g., the first trench 120 and the second trench 121). For example, as described herein, the trenches may correspond to half-cylindrical shaped recesses, whereby the diameter of a trench (e.g., trench 120 or 121) matches (e.g., substantially equals) the diameter of the void 118. In this way, when blocks are stacked in a wall assembly (e.g., either in a transverse interconnection or a linear interconnection), the respective voids may be aligned so as to form a continuous passage. For example, core columnar voids may be aligned according to matching voids (e.g., the second void 122 and/or the third void 124), and head joint columnar voids (e.g., void 118) may also be aligned according to matching trenches. It should be should be understood that the shape and/or dimensions of the voids (e.g., void 118) and trenches need not be identical. In any case, when blocks are mated, a continuous passage is formed via the respective trenches and/or voids being aligned (e.g., partially and/or substantially completely aligned).
In diagram 200 of
In some embodiments, the dimensions of the full-length (e.g., standard) block may be such that a length (e.g., length 240, shown in the bottom view 206) of the block (e.g., the length of the top/bottom surface) is approximately twice a width (e.g., width 238) of the top/bottom surface of the block. The height of the block may be any suitable measurement relative to the length 240 and width 238. For example, in one embodiment, as described further below, and, using inches as a unit of measurement, the length 240 may be (e.g., nominally) twelve inches, the width 238 may be six inches, and the height may be six inches. In another embodiment, the length 240 may be twenty-four inches, the width 238 may be twelve inches, and the height may be six inches. It should be understood that any suitable set of dimensions may be used to perform embodiments herein. For example, a length 240 of the block may be any suitable number within a particular range (e.g., a range of one inch to ten feet). Accordingly, the length 240 may be either six inches, seven inches, 1.5 feet, two feet, or any suitable number with the particular range, and the width 238 may be approximately half the selected length 240. In some embodiments, a half-length block may be such that the length of the half-length block matches the width of the half-length block. For example, a half-length block may have a length of six inches and a width of six inches.
Turning to the top view 202 of the top surface in further detail, as described herein, in one embodiment, two projections (e.g., a first projection and a second projection) may protrude beyond the top surface along the first axis 250, whereby each projection is symmetrical along the second axis 252 and the third axis 254. Accordingly, the projection may be symmetrical in the four quadrants formed by an intersection of the second axis 252 and the third axis 254 at an origin point (e.g., a center of a respective projection). In some embodiments, each projection may correspond to a cross-shaped projection. However, embodiments should not be construed to be so limiting, as described herein. For example, a square-shaped (or other suitable polygonal-shaped) projection may also be used. As described herein, by ensuring that the projection (and/or recess) is symmetric with respect to four quadrants, embodiments enable interconnecting features of a block to support both linear and transverse interconnectivity.
In some embodiments, whereby a projection corresponds to a cross-shaped key, the dimensions of the cross-shaped key (forming a part of a keyway array on the top surface) may be determined to be proportionate to the dimensions of the block (e.g., length 240 and width 238). Using the example above, whereby the block top/bottom surface length is nominally twelve inches and the block top/bottom surface width is nominally six inches, a length 210 of a base of the first cross-shaped projection may be 2½ inches along the third axis 254. A length 212 of an upper surface of the first cross-shaped projection may be two inches along the third axis 254. In some embodiments, a slightly smaller length of 1 15/16 inches may be utilized as the length 212, to allow for slight adjustments of the positioning of the mated blocks during the initial erection of a wall assembly. This slightly smaller length may similarly be applied to other dimensions of other elements, as described further below. Also, note that the length 210 may be longer than the length 212, to allow for an angled mating between a projection and a recess, which may enable a more efficient mating process. For example, as described further below and depicted by the end view 208 of
Similar to as described regarding the first cross-shaped projection, the second cross-shaped projection (to the right of the first cross-shaped projection in diagram 200) may also have a length 211 of a base of the projection that corresponds to 2.5 inches along the second axis 252. A length 213 of an upper surface of the first cross-shaped projection may be 2 inches (or 1 15/16 inches). Note that the length 210 of the base of the first cross-shaped projection may match the length 211 of the second cross-shaped projection, while the length 212 of the first cross-shaped projection may match the length 213 of the second cross-shaped projection. In this way, embodiments may further enable both transverse and linear interconnectivity in a wall assembly.
As described herein, the full-length standard block also may contain one or more voids and trenches. For example, as depicted in the top view 202, a void 214 may exist (e.g., a core columnar void), whereby the void 214 is defined in part by a passage through the block (e.g., along the first axis 250) that runs from the top surface (shown by the top view 202) to the bottom surface (shown by the bottom view 206). In some embodiments, whereby the passage may be cylindrically shaped, a diameter of the core columnar void 214 may be approximately 2 7/16 inches. It should be understood that this is only one example diameter. Any suitable diameter (and/or dimension, depending on the polygonal shape of the void) may be used, for example, 2.5 inches, 3 inches, 5 inches, etc. This may depend, for example, on the other relative dimensions of the block. In some embodiments, the core columnar void 214 may exist at a center of a top surface of a projection. For example, suppose that an origin of the second axis 252 and the third axis 254 is at a center of the surface of a projection. In this example, a center of the void 214 may be at the origin. However, embodiments should not be construed to be so limiting. In one example, instead of the center of the core columnar void 214 existing at the origin, the core columnar void 214 may exist slightly above (e.g., 1/16, 2/16, or 3/16 inch), below, to the left, or to the right of the origin. In any case, the core columnar void may be located such that, when the block is mated with another block (e.g., above or below the block), the core columnar void 214 may be aligned with the other block so as to form a continuous passage. In some embodiments, both core columnar voids of the block may have similar (e.g., the same) dimensions, thus supporting both linear and transverse interconnectivity.
In some embodiments, another void 218 may exist, which may correspond to a head joint full columnar void, as described herein. In some embodiments, the void 218 may be defined in part by a passage that runs through the block along the first axis 250. For example, the two projections may be interconnected at a projection interconnection location (e.g., visualized by the center vertical dotted line of the top view 202). The void 218 may run from a surface of the projection interconnection location to a surface of a recess interconnection location (discussed below). In some embodiments, the void 218 may be one inch in diameter. However, embodiments should not be construed to be so limiting. For example, the diameter of the void 218 may be ½ inch, 1½ inches, 2 inches, or 3 inches, 1 foot, etc., depending, on the dimensions of the block and the requirements for the wall assembly. Similar to the void 214, it should be understood that, although the void 218 is depicted as being cylindrically shaped, embodiments should not be construed to be so limited. For example, a square or other suitable polygonal shape may be used.
In some embodiments, two trenches (a first trench and second trench) may exist on both endwalls of the block. For example, a first trench 216 is depicted as extending into the endwall on the right side of the block (e.g., via the top view 202). In some embodiments, the relative positions of the void 218 and the two trenches (e.g., including the first trench 216) may be such that the void 218 exists between the first trench 216 and the second trench along the second axis 252. For example, the void 218 may be at a center of the block, to support linear and transverse interconnectivity. However, in some embodiments, the void 218 may be positioned to the left or right of the center, whereby a continuous passage is still formed when the block is mated with another block above or below. In some embodiments, the first trench 216 may have a similar (e.g. same) dimension as the void 218. For example, the first trench 216 may correspond to a half-cylindrically shaped trench, whereby the diameter of the half-cylinder is the same as the diameter of the void 218. However, embodiments should not be construed to be so limiting. For example, a first width of the first trench 216 may be defined by a start point and an endpoint along the third axis 254. Also, a second width of the second trench may be defined by a start point and an end point along the third axis 254, whereby the start point of the second width exists between the start point and the end point of the first width along the third axis 254. Meanwhile, a width (e.g., diameter) of the void 218 may be defined by a start point and an end point along the third axis 254. The start point of the width of the void 218 may exist between respective endpoints of a first width (e.g., diameter) of the first trench 216 and a second width (e.g., diameter) of the second trench, so that the width of the void 218 overlaps with both the first width and the second width along the third axis 254.
Turning to the sidewall view 204 in further detail, the sidewall view 204 may depict a view of a first sidewall of a pair of sidewalls, including the first sidewall and a second sidewall that are parallel to one another. The pair of sidewalls may be connected by the top surface (shown by the top view 202) and the bottom surface (shown by the bottom view 206), whereby the pair of sidewalls (e.g., generally planar) have end edges generally perpendicular to the top surface and the bottom surface. As depicted, the first sidewall may have a length that matches the length 640 (e.g., twelve inches). The length may be divided into four sub-lengths, including sub-length 220, sub-length 222, sub-length 224, and sub-length 226. In some embodiments, the sub-lengths may be evenly divided into three-inch increments. In some embodiments, the length of the overall sidewall may be slightly less than twelve inches (e.g., 11 30/32 inches). In this case, two of the sub-lengths (e.g., sub-length 220 and sub-length 226) may each be 2 31/32 inches, while the other two sub-lengths may respectively be three inches. Note that, as visualized by the vertical dotted lines that divide each sub-length and run through the top surface, the sidewall, and the bottom surface, a relative position of the elements of the block may be determined.
Turning to the bottom view 206, elements of the bottom surface are depicted that may be associated with elements of the top surface. For example, in one embodiment, two recesses (e.g., a first recess and a second recess) may extend into the bottom surface along the first axis 250. Similar to the projections, each recess may also be symmetrical along the second axis 252 and the third axis 254 (e.g., symmetrical in four quadrants). Also, while the two recesses of the bottom surface are depicted as being cross-shaped recesses, embodiments should not be construed to be so limiting. Generally, a recess may be shaped such that the recess may be able to be mated with a projection.
In some embodiments, whereby a recess corresponds to a cross-shaped recess (e.g., a key recess), the dimensions of the cross-shaped recess may be determined to be proportional to the dimensions of the block. Again, using the example above, whereby the block top/bottom surface length 240 is nominally twelve inches and the block top/bottom surface width 238 is nominally six inches, a length 230 of a base of the first cross-shaped recess (e.g., coplanar with the bottom surface) may be 2⅝ inches along the third axis 254. A length 232 of an upper surface of the first cross-shaped projection may be 2 1/16 inches along the third axis 254. Similar to the projection above, note that the length 230 is longer than the length 232, to allow for an angled mating between a projection and a recess, which may enable a more efficient mating. Note also that the length 210 of the base of the projection (e.g., 2½ inches) may be slightly less than the length 230 of the base of recess (e.g., 2⅝ inches) along the third axis 254 (and similar, comparing the length 212 to the length 232). This may also allow for adjustments in positioning of the blocks during erection of a vertical structure.
In some embodiments, the dimensions of a second cross-shaped recess may be similar to (e.g., be the same as) the first cross-shaped recess. For example, a length 231 of a base of the second cross-shaped recess (coplanar with the bottom surface) may be, for example, 2⅝ inches along the second axis 252. A length 233 of an upper surface of the second cross-shaped recess may be, for example, 2 1/16 inches. In this way, embodiments may further enable both transverse and linear interconnectivity in a wall assembly.
In some embodiments, there may be a gap between the two recesses (and projections) along the length 240 of the block. For example, as depicted by the bottom view 206, a first gap along the second axis 252 between a base of the first recess and the base of the second recess (e.g., both coplanar with the bottom surface) may have a length 234 of, for example, 3 15/16 inches. Also, a second gap along the second axis 252 between a surface of the first recess and a surface of the second recess may have a length 236 of, for example, 3⅜ inches. Note again that the length 234 is longer than the length 236, which may allow for an angled mating between a projection and a recess.
Turning to the endwall view 208 in further detail, the endwall view 208 may depict a view of a first endwall of a pair of endwalls, including a first endwall and a second endwall that are parallel to one another. The pair of endwalls may be connected by the top surface and the bottom surface, whereby the pair of endwalls are transverse and joined to the pair of sidewalls, and whereby the pair of endwalls respectively have a length 251 along the third axis 254 that is nominally half the length 240 of the block. For example, assuming that the length 240 corresponds nominally to twelve inches (e.g. practically 11 15/16 inches), the length 251 may correspond to nominally six inches. For example, dividing the length 251 into two parts, a first length 248 may be 2 63/64 inches, and a second length 249 may be 2 63/64 inches. Additionally, a length 242 may measure the length of a protrusion along the first axis 250, which may correspond to approximately half an inch. Similarly, a length 244 may measure the length of a recess along the first axis 250, which may also correspond to approximately half an inch. Also, a trench that extends into the endwall is depicted in the endwall view 208. In this depiction, a radius 246 of the half-cylindrical trench may be approximately one-half inch (i.e., thus, forming a one-inch diameter). It should be understood that the above set of dimensions provide measurements for one possible embodiment for block that has a length 240 of approximately twelve inches (e.g., 11 15/16 inches), and a width 238 of approximately six inches (e.g., 5 31/32 inches). However, as described above, any suitable dimension(s) may be used that are proportional other dimensions of the block, such that both linear and transverse interconnectivity are realized. For example, for a given length 240 and/or width 238 selected from a range of possible values (as described herein), a proportional set of dimensions (e.g., length 210, length 212, length 211, length 220, length 246, etc.) may be selected. For example, instead of being 2.5 inches, the length 210 of the base of the projection may be 1 inch, 5 inches, 10 inches, or any suitable value within a range (e.g., a half-inch to one foot) that is proportional to the length 240 and width 238 of the block.
Turning to the elements and various interconnections illustrated by diagram 300 in further detail, the half-length block 302 may be stacked on top of the full-length standard block 306, whereby a first endwall of the half-length block 302 is coplanar with a first endwall of the full-length standard block 306. A second endwall of the half-length block 302 may be adjacent to a first endwall of the full-length standard block 304. Also, the second endwall of the half-length block 302 may be located at a midpoint of the length of the top surface of the lower full-length standard block 306. Meanwhile, the full-length standard block 304 may be interconnected (e.g., mated) with both the full-length standard block 306 and 308 in a running bond application. In this embodiment, based at least in part on the endwall of the half-length block 302 being coplanar with the endwall of the full-length standard block 306, a running bond application of courses may be supported, while also enabling end blocks of each course to have endwalls that are coplanar with an adjacent wall. It should be understood that any suitable combination of block types may be interconnected, based on the interconnecting features described herein. For example, while the lower blocks (e.g., the full-length standard blocks 306 and 308) correspond to standard blocks in this example, in another embodiment, they may instead correspond to full-length flat-bottom blocks at the base of a wall assembly.
In some embodiments, as described herein, the projections and recesses of each block may enable the block to be mated with one or more other blocks. For example, a recess 312 of the full-length standard block 304 may be mated with a projection 322 of the full-length standard block 306. Note that, in some embodiments, a running bond application may be enabled based in part on each full-length block having at least two projections and corresponding recesses. For example, the recess 312 may correspond to a first recess of the full-length standard block 304, which is mated with the projection 322 (e.g., one of two projections of the full-length standard block 306). The full-length standard block 304 may also have another recess that is mated to a projection of the full-length standard block 308, as depicted in
As described herein, trenches and voids of the different blocks of diagram 300 may also support various interconnections between the blocks in the stacked assembly. For example, a first void 314 may be formed based on an alignment between a trench of the half-length block 302 and another trench of the full-length standard block 304. The first void 314 may be further aligned with a void of the lower full-length standard block 306 (e.g., existing at a midpoint of the block and running through the block, similar to the void 118 of
Similarly, core columnar voids may also be aligned between the different blocks to form a continuous vertical passage from the base of the assembly to a top portion of the assembly. As a representative example, a void 320 (e.g., a core columnar void) of the full-length standard block 304 may be aligned with another void of the same type (e.g., another core columnar void of the full-length standard block 308) to form a portion of a continuous passage. This continuous passage may later may receive cast-in-place cement grout and reinforcing rods, thus providing structural support to bear structure loads.
Turning to the full-length block type in further detail, the four sub-types of blocks include: a standard block type 402, a flat-top block type 406, a U-shaped block type 410, and a flat-bottom block type 414. The standard block type 402 may include at least one projection that protrudes beyond a top surface of the block, and at least one recess that extends into a bottom surface of the block. In the example of
Turning to the half-length block type in further detail, the four sub-types of blocks include: a half-length standard block type 404, a half-length flat-top block type 408, a half-length U-shaped block type 412, and a half-length flat-bottom block type 416. In some embodiments, the half-length block type may be half the length of the standard block type. Accordingly, and for example, the half-length standard block type 404 may be half the length of the standard block type 402. In some embodiments, the half-length block type may include at least two trenches on each endwall, similar to the trenches of the corresponding full-length block type. In some embodiments, the half-length block type may include a void (e.g., similar to a core columnar void of a full-length block) that runs through the block, as illustrated in
A base course of the wall assembly may include a course of blocks, with a base block 507 being a representative block of the base course. In this example, the base block 507 is a flat-bottom block type (e.g., full-length). A base block 508 of the sidewall view 504 may correspond to the same block as base block 507, but seen from a sidewall perspective. A base block 510 of the second endwall view 506 may be positioned at an opposite end of the wall from the base block 507. The base block 510 may also be a flat-bottom block type (e.g., full-length). It should be understood that, any suitable combination and/or ordering of full-length and half-length blocks may be used to form a course of blocks.
Turning to intermediate courses of the wall assembly, a first half-length standard block 512 of a second course of the sidewall view 504 may be interconnected above the lower base block 508. Note that a recess of the first half-length standard block 512 may interconnect with one of the projections of the base block 508. On the opposite end of the second course, as depicted by the second endwall view 506, a second half-length standard block 514 may be interconnected above another lower base block. Accordingly, in this example, the second course may have two half-length standard block types that bookend the second course. In a third course of the wall assembly, a standard block 516 is depicted, which may be similar to the standard block 402 of
Turning to the top course of blocks of the wall assembly, a full-length U-shaped block 518 is depicted in the first endwall view 502 as an end block. The full-length U-shaped view 518 may correspond to U-shaped block 310 of
A full-length flat-top block 524 may also be positioned in the top course of blocks at an opposite end from the full-length U-shaped block 518, as depicted in the first endwall view 502. A full-length flat-top block 526 of the second endwall view 506 and a full-length flat-top block 528 of the sidewall view may each provide different perspectives of the same block. Note that, as described herein, the full-length flat-top block 528 contains three voids: a first void 530 (e.g., a head joint full columnar void), a second void 532 (e.g., a core columnar void), and a third void 534 (e.g., another core columnar void). The full-length flat-top block 528 also contains two trenches extending into each of the respective endwalls of the block 528. Note that each of these voids may be aligned with lower blocks to form a continuous passage extending vertically through the length of the wall assembly. Additionally, in some embodiments, one or both of the trenches align with another adjacent trench of another block to form a void, which in turn forms a portion of a continuous passage. A representative example is depicted by voids 536 and 538 of the first endwall view 502, which are respectively formed from adjacent trenches of endwalls of U-shaped blocks on the top course. It should be understood that the illustration of different block types and block positions of diagram 500 is representative of one possible wall assembly. Any suitable arrangement of block types and block positions to form interconnections may be envisioned by embodiments disclosed herein.
Turning to diagram 600 in further detail, a first full-length flat-top block 602 may be positioned as an end block at the ninety degree turn of the wall assembly. The block 602 may be stacked above a lower full-length standard block 604 that is positioned transverse to the block 602, such that an endwall of the block 604 is coplanar with a sidewall of the block 602. Note that, based in part on the interconnecting features of the block types, the block 602 may transversely interconnect with block 604 while another second full-length flat-top block 606 linearly interconnects with the lower block 604. Note that other blocks (e.g., standard intermediate blocks, flat-top blocks, etc.) of the wall assembly may also be interconnected (e.g., linearly interconnected or transversely interconnected), similar to as described herein (e.g., with respect to
As depicted in diagram 600, embodiments may enable continuous passages to be formed not only for courses of blocks that are linearly interconnected, but also for transverse stacking of blocks. For example, consider that block 602 includes at least a first void 608 (e.g., a core columnar void) and a second void 610 (e.g., a head joint full columnar void). As described herein, because of the way the blocks are configured to mate (e.g., between block 602 and block 604), a continuous passage may be formed from a surface of the flat-top block 602 to a base block of the wall assembly. Similarly, the second void 610 may also form a portion of a continuous passage from a surface of the flat-top block 602 to a base block of the wall assembly. In some embodiments, the continuous passage may have a consistent shape (e.g., cylindrical, square) throughout the passage. In some embodiments, the continuous passage may have varying shapes (e.g., varying perimeters, diameters, etc.) throughout the passage. In some embodiments, after wall is assembled, one or more voids may be further crafted (e.g., manually shaped). For example, a trench may be manually formed within a sidewall of block 602 in order to align with a trench at endwall of the block 606 to form a head joint full columnar void. In some embodiments, a full void may be formed by aligning trenches of adjacent endwalls of blocks. For example, a third void 612 may be formed by aligning a trench of an endwall of block 602 with another trench of an endwall of the block that is linearly interconnected with the block 602 in the same top course. The third void 612 may form a portion of another continuous passage (e.g., a head joint full columnar void) from the top surface of the wall to the base of the wall.
As described herein and further depicted in diagram 600, the interconnecting features of the blocks may enable the wall to be efficiently (e.g., rapidly) assembled and reinforced. For example, the projections and recesses of the blocks may enable the blocks to be efficiently stacked such that voids and trenches of the block are aligned to form continuous columnar cavities. Subsequent to assembling the wall, the columnar cavities may be filled with one or more materials. For example, the first void 608 may correspond to a portion of a core columnar void. The core columnar void cavity may be filled with cast-in-place cement grout and reinforcing rods (e.g., a vertical reinforcing steel rod 614) that run along the continuous passage to the base of the wall assembly. Similar vertical reinforcing steel rods may be placed in other core columnar void passages to reinforce the wall in any suitable arrangement (e.g., inserting a rod in staggered selected vertical core columns within the wall assembly). The steel rods may extend into a horizontal cast-in-place bond beam 616 of reinforcing steel at the top of the wall. Additionally, a cast-in-place concrete bond beam 618 (cut away for clarity in
Embodiments of block configurations described herein thereby provide a mechanism for not only efficiently assembling a wall assembly, but also for subsequently efficiently and securely reinforcing and insulating the wall assembly. For example, the post-erection coating at the exterior surface provides horizontal reinforcing, while the cast-in-place concrete bond beam at the top may horizontally distribute loads throughout the wall assembly. Additionally, the above-described steel rods may correspond to tensioning devices that include high-tensile threaded steel rods, case hardened washers with nuts, and rod shroud jackets that separate the rods from the cementitious material that encapsulate the rods. The rods may be anchored in the foundation below and pass through the bond beam at the top of the wall assembly. The nuts may be torqued to specific limits to impose tension on the rods and thereby impose a down force load at the top of the bond beam. This down force compression by the tensioning device may effectively simulate a gravity load on the wall below. It should be understood that these features may be enabled based at least in part on the interconnecting features of the blocks, which enable the various cavities to be filled with cementitious material.
The invention has now been described in detail for the purposes of clarity and understanding. However, those skilled in the art will appreciate that certain changes and modifications may be practiced within the scope of the appended claims. It is to be understood that any workable combination of the features and capabilities disclosed above in the various embodiments is also considered to be disclosed.
This application claims the benefit of priority to U.S. Provisional Patent Application No. 62/890,368, filed Aug. 22, 2019, entitled “A cementitious building block with interconnecting features” (Atty. Docket No. 533323711), the contents of which are herein incorporated in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62890368 | Aug 2019 | US |
