MASONRY BLOCK, LINK, AND METHOD OF INTERLOCKING

TECHNICAL FIELD

The disclosure generally relates to building blocks or bricks or masonry articles, and more specifically to interlocking masonry articles having connecting features designed for interlocking and stacking with mortar-less joints to form continuous wall sections.

BACKGROUND

In the past, efforts have been made to overcome the shortfalls of various building elements such as bricks, blocks whether, clay, cinder or cement, and the like. Masonry building elements are laid course by course on a foundation or footing, in standard configurations wherein a course of grout or mortar lies between each row and column of masonry elements and between each adjacent masonry element. Open mortar joints are relatively porous allowing some water penetration of the joint and mortar adheres poorly to the masonry elements. Consequently, the weakest link in masonry construction is the mortar joint, which is a poor barrier to heat, cold, and moisture and which may expand and contract with hot and cold weather cracking the mortar resulting in deterioration of the appearance and strength of the brick wall.

Bricks have been used for years for the construction of buildings, roads and walls. For most of that time, bricks have been made solid from clay or similar materials, cast and baked in a kiln or dried. To build with bricks requires overlapping staggered courses so as to produce adequate strength for buildings, roads and walls. More recently, it has been possible to make bricks from more convenient materials, such as concrete. Moreover, this has allowed fabrication of different shapes and contours of bricks.

When it is desired to create a wall with a corner or a curve, there is an angular gap or overlaps between the ends of the bricks or the male and female portions restrict corner or curve construction or the interlocking features may not mate depending on the curvature of the wall. Moreover, some brick designs have sharp corners or edges that may break during shipping and handling resulting in a number of broken bricks.

Moreover, mortarless bricks have been designed with alternating male and female ends and peak and valley cross section configurations; however, these brick designs have been difficult to manufacture with existing tooling due to multiple contours and have not meet standard sizing of eight or sixteen inch bricks resulting in non-standard pallet requirements for packaging and shipping.

Therefore, it is readily apparent that there is a recognizable unmet need for a masonry block, link, and method of interlocking that functions as an interlocking building block system to readily form continuous wall sections with mortar-less joints without the need for reinforcement with rods or posts or filled with concrete or both and, thereby, imparting strength, ease of manufacturing, palleting, and durability to such wall and its corners or a curved wall sections.

SUMMARY

Briefly described, in an example embodiment, the present apparatus and method overcomes the above-mentioned disadvantages and meets the recognized need for a masonry block, link block and method of interlocking including, in general, a masonry article having one or more sidewalls, top and bottom, and first and second ends configured with a horizontal and vertical locking mechanism, wherein top and bottom includes first axis locking mechanism, wherein the top surface is formed with at least one stepped section having a base that begins with a level footing and the bottom opposite surface formed with at least one other stepped section having a base that begins with a level footing to releasably receive one of the top, and wherein first and second ends include contoured receptacles to releasably receive a matching configured link block having opposite male contour surface to form second axis locking mechanism, and, thus, functions to create a free-standing mortar-less wall block unit assembled as a plurality of bricks without the need for reinforcement with rods or posts or filled with concrete or both and, thereby, imparting strength and durability to a wall of masonry blocks having interlocks in two different planes.

In use, a collection of locking masonry block system having two interlocking systems 1) a vertical locking mechanism configured of at least one matched stepped section integrated into the top and bottom and 2) a horizontal locking mechanism configured of block ends having contoured receptacles to releasably receive a male configured link enabling a mortar free stacking of a plurality of masonry blocks to form a wall, and wherein corner and curved masonry block configuration enables corner, tower and curved wall construction.

In a further exemplary embodiment, a masonry block used to form at least one portion of a wall configured with two or more courses, the masonry block includes a first side and a second opposed side, a first end and a second opposed end extend from the first side to the second side, wherein the first end and the second end are each configured with a contour receptacle portion therein, and a first load bearing and a second opposed load bearing surface extend, parallel to and match one another from the first side to the second side, and extend from the first end to the second end, wherein the first surface configured with one or more tiered sub-surfaces and the second surface configured with one or more tiered sub-surfaces to releasably couple one of the first surface.

In a further exemplary embodiment, a link block used to form at least one portion of a wall configured with two or more courses, the link block is configured with a front contoured divot and a back contoured divot, a first contoured end and a second contoured end extend from the front contoured divot to the back contoured divot.

In a further exemplary embodiment, a set of masonry blocks used to form at least one portion of a wall configured with two or more courses, includes a masonry block configured with a first side and a second opposed side, a first end and a second opposed end extend from the first side to the second side, wherein the first end and the second end are each configured with a contour receptacle portion therein, a first load bearing and a second opposed load bearing surface extend, parallel to and match one another from the first side to the second side, and extend from the first end to the second end, wherein the first surface configured with one or more tiered sub-surfaces and the second surface configured with one or more tiered sub-surfaces to releasably couple one of the first surface, and a link block configured with a front contoured divot and a back contoured divot, a first contoured end and a second contoured end extend from the front contoured divot to the back contoured divot, wherein the masonry blocks configured butted end to end and releasably coupled by the link block form a first axis locking mechanism, wherein the masonry blocks configured stacked one on top of the other releasably coupled between the first load bearing surface and the second opposed load bearing surface form a second axis locking mechanism.

In a further exemplary embodiment of a method of forming at least a portion of a wall of masonry articles configured with two or more courses, including the steps of providing a masonry block configured with a first side and a second opposed side, a first end and a second opposed end extend from said first side to said second side, wherein said first end and said second end are each configured with a contour receptacle portion therein, a first load bearing and a second opposed load bearing surface extend, parallel to and match one another from said first side to said second side, and extend from said first end to said second end, wherein said first surface configured with one or more tiered sub-surfaces and said second surface configured with one or more tiered sub-surfaces to releasably couple one of said first surface, providing a link block configured with a front contoured divot and a back contoured divot, a first contoured end and a second contoured end extend from said front contoured divot to said back contoured divot, assembling a first course of masonry articles wherein masonry blocks configured butted end to end and releasably coupled by said link block form a first axis locking mechanism, and assembling a second course of masonry articles wherein said masonry blocks configured stacked one on top of the other releasably coupled between said first load bearing surface and said second opposed load bearing surface form a second axis locking mechanism.

Accordingly, a feature of the masonry block, link, and method of interlocking bricks is 1) a vertical locking mechanism configured of at least one matched stepped section integrated into the top and bottom and 2) a horizontal locking mechanism configured of block ends having contoured receptacles to releasably receive a male configured link.

Another feature of the masonry block, link, and method of interlocking bricks is its ability to provide a masonry article to readily form continuous wall sections with mortar-less joints.

Another feature of the masonry block, link, and method of interlocking bricks is its ability to provide a masonry brick that is not reinforced with rods or posts or filled with concrete/grout or both.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide for simple and efficient assembly including the ability to adjust side-by-side placement of masonry articles to correct length mismatches while laying a structure.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to accommodate a variety masonry articles, such as size, shape, and function.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide a stylish masonry block to personalize the appearance of the masonry article for aesthetic, display, marketing and sales purposes.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide a low cost, mortar-less brick wall construction.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide interlocks in two different planes, first axis and a second axis locking mechanism.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide a masonry article formed of a disposable material, such as recycled material.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide interconnecting passageways in two planes for installation for plumbing or electrical supply lines and the like.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide mortar free stacking masonry article for wall construction, including for corners and/or curved sections.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide a plurality of interlocking masonry articles that interlock in a top to bottom (vertical) mode as well as in an adjacent side by side (horizontal) mode so such bricks do not have to be reinforced with rods or posts, mortar, or filled with concrete or both.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide methods for assembling structures or walls using the plurality of interlocking masonry articles.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to eliminate the use of plum or level tools during wall construction from the foundation layer up.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to eliminate the cutting and chipping of bricks and blocks on the construction site.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to eliminate the use of mortar during wall construction.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to eliminate the need for field modifications to the brick or block.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide one masonry block interlockable or adapted to fit with one link.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide vertical channels to accommodate electrical wiring, plumbing, communication cable, and the like.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide masonry blocks meeting standard sizes, such as eight and sixteen inch block configurations.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide masonry blocks with reduced contours, edges, and angles to meet current manufacturing and tooling mold capabilities.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide masonry blocks that meet current pallet stacking configurations.

Yet another feature of the masonry block, link, and method of interlocking bricks is its ability to provide masonry blocks without sharp or pointed edges which may break during stacking and/or shipping.

These and other features of the masonry block, link, and method of interlocking bricks will become more apparent to one skilled in the art from the following Brief Description of the Drawings, Detailed Drawings, Detailed Description and Claims when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present masonry block, link, and method of interlocking bricks or the like will be better understood by reading the Detailed Description of the embodiments with reference to the accompanying drawings, in which like reference to numerals denote similar structures and refer to like elements throughout, and in which:

FIG. 1 is a top, side, end, and perspective view of an example receptacle embodiment of the masonry block;

FIG. 2 is a top, side, and perspective views of an example embodiment link block;

FIG. 3 a top and perspective view of first course of a wall of masonry block and half masonry block of FIG. 1 and link assembly of FIG. 2 to form first axis locking mechanism;

FIG. 4 is a side and perspective view of an example embodiment wall W (two or more courses) of an assembly of bricks and links shown in FIG. 1 and FIG. 2 to form first and second axis locking mechanism;

FIG. 5 is a top, side, end, and perspective view of an example acute angle alternate embodiment of the masonry block of FIG. 1;

FIG. 6 is a top and perspective view of an example embodiment circular wall W of an assembly of masonry blocks shown in FIG. 5;

FIG. 7 is a top, end, side, and perspective view of an example 90 degree corner alternate embodiment of the masonry block of FIG. 1;

FIG. 8 is a top, end, side, and perspective view of an example 90 degree corner and joiner alternate embodiment of the masonry block of FIG. 1;

FIG. 9 is a top, side, and perspective view of an example embodiment planter column having ninety degree corner walls W of an assembly of masonry blocks shown in FIG. 7 or FIG. 8;

FIG. 10 is a top, end, side, and perspective view of an example octagonal alternate embodiment of the masonry block of FIG. 1;

FIG. 11 is a top, end, side, and perspective view of an example octagonal assembly and joiner alternate embodiment of the masonry block of FIG. 10;

FIG. 12 is a top and perspective view of an example embodiment octagonal landscaping column C of an assembly of masonry blocks shown in FIG. 10 and FIG. 11;

FIG. 13 is a top, end, side, and perspective view of an alternate example embodiment of the masonry block of FIG. 1;

FIG. 14 is a perspective view of an example embodiment wall W (two or more courses) of an assembly of masonry blocks and links shown in FIG. 13 and FIG. 2;

FIG. 15 is a top, end, side, and perspective view of an example acute angle alternate embodiment of the masonry block of FIG. 13;

FIG. 16 is a top and perspective view of an example embodiment wall W of an assembly of masonry blocks and links shown in FIG. 15 and FIG. 2; and

FIG. 17 is a flow diagram of a method of interlocking masonry blocks and links in two or more planes, interlock in a first horizontal plane, and interlock in a second vertical plane.

It is to be noted that the drawings presented are intended solely for the purpose of illustration and that they are, therefore, neither desired nor intended to limit the disclosure to any or all of the exact details of construction shown, except insofar as they may be deemed essential to the claimed invention.

DETAILED DESCRIPTION

In describing the exemplary embodiments of the present disclosure, as illustrated in FIGS. 1-17 specific terminology is employed for the sake of clarity. The present disclosure, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions. Embodiments of the claims may, however, be embodied in many different forms and should not be construed to be limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples, and are merely examples among other possible examples.

Referring now to FIG. 1 by way of example, and not limitation, there is illustrated an example receptacle embodiment of the masonry article, building product, brick or block and a collection thereof, such as masonry block 10. Preferably, masonry block 10, or a plurality of blocks thereof, includes formed, cut, molded or shaped solid structure having one or more faces, sides, ends, or surfaces, such as sides: front 21, back 22, top 23, and bottom 24, and first receptacle 25 and second receptacle 26, such masonry block 10 arranged preferably as, a rectangle-like sided structure. It is contemplated herein that configurations other than rectangle-like sides forming preferably receptacle ends and stepped top and bottom structure for masonry block 10 may be utilized herein or others known to one of ordinary skill in the art. Moreover, first receptacle 25 and second receptacle 26 are preferably formed as a horseshoe shape female portion, contour, indentation or cylindrical shaped seat (wherein side end 27 and 28 are preferably angle A, approximately ninety degrees relative to sides 21 and 22), but other shapes for first receptacle 25 and second receptacle 26 are contemplated herein, which traverse vertically and approximately top to bottom of masonry block 10, so as to cooperate and interlock with link block 12 between two masonry blocks 10. Preferably, lip 29A and 29B of contoured first receptacle 25 and lip 29C and 29D of contoured second receptacle 26 may be utilized to grip, link, interlock or affix masonry block 10 with link block 12.

Masonry block 10 and link block 12 are preferably formed, molded or configured from a suitable material, such as clay, cement, fiber reinforced, polymer or alternative resin, adhesive, plastic, paper, cardboard, rubber, fiber, foam filled material, synthetic, rubber, wood, metal, aluminum, alloy, steel, or shape memory metal or any rigid or semi-rigid composite material or the like and any manufacturing method, capable of providing structure to masonry block 10 and link block 12 known to one of ordinary skill in the art. Preferably, the material includes other suitable characteristics, such as weight, strength, durability, water-resistance, wearability, chemical inertness, oxidation resistance, ease of workability, longevity, or other beneficial characteristic understood by one skilled in the art.

It is recognized herein that sides 21 and 22 are preferably standard industry brick or block sizes, such as eight and sixteen inch length block configurations, but other sizes and shapes for masonry block 10 are contemplated herein.

Preferably, top 23 of masonry block 10 includes a series of surfaces, load bearing surfaces, or tiered sub-surfaces, including plateau 23.1 having adjacent one or more lateral, base or footings, such as footer(s) 23.3A/23.3B with transition surface(s) 23.2A/23.2B positioned therebetween plateau 23.1 and footer(s) 23.3A/23.3B, and edge(s) 23.4A/23.4B disposed proximate footer(s) 23.3A/23.3B. Top 23 is preferably formed substantially as a stepped transition profile shape, but other shapes and sizes for top 23 are contemplated herein, which traverse horizontally and approximately end-to-end of masonry block 10. Furthermore, bottom 24 preferably includes a series of matching surfaces to top 23, including plateau 24.1 having adjacent one or more lateral, base or footings, such as footer(s) 24.3A/24.3B with transition surface(s) 24.2A/24.2B positioned therebetween plateau 24.1 and footer(s) 24.3A/24.3B, and edge(s) 24.4A/24.4B disposed proximate footer(s) 24.3A/24.3B. Bottom 24 is preferably formed substantially as a stepped transition profile shape, but other shapes and sizes for bottom 24 are contemplated herein, which traverse horizontally and approximately end-to-end of masonry block 10. It is recognized herein that top 23 and bottom 24 are preferably formed with similar surfaces to fit, mate, or match top 23 and bottom 24 when stacked one on top of the other.

Referring now to FIG. 2 by way of example, and not limitation, there is illustrated an example link embodiment of the masonry system, such as link block 12. Preferably, link block 12, or a plurality of links thereof, includes formed, cut, molded or shaped solid structure having one or more faces or surfaces, such as sides: front contoured divot 31, back contoured divot 32, top 33, and bottom 34, and first contoured end 35 and second contoured end 36. It is contemplated herein that configurations other than rectangle-like structure or contoured, such as other locking structures may be utilized herein between link block 12 and masonry block 10 or others known to one of ordinary skill in the art. Moreover, first contoured end 35 and second contoured end 36 are preferably formed substantially as corresponding horseshoe shaped male portion, protrusion, or contoured shaped nose portion, but other shapes for first contoured end 35 and second contoured end 36 are contemplated herein, which traverse vertically and approximately top to bottom of link block 12.

It is recognized herein that sides, such as front contoured divot 31 and back contoured divot 32 are preferably standard industry brick or block sizes, such as four and eight inch height block configurations, but other sizes and shapes for link block 12 are contemplated herein.

Referring now to FIG. 3 by way of example, and not limitation, there is illustrated an example first course of a wall of masonry block of FIG. 1 and link block of FIG. 2 to form first axis locking mechanism 30A when assembled.

First Axis Interlocking Feature

Preferably, one or more masonry block 10 are positioned end-to-end in a straight line to form one or more courses, where second receptacle 26 of first masonry block 10.1 is positioned proximate or butted up against first receptacle 25 of second masonry block 10.2 linearly along first axis 30B. Preferably link block 12 is positioned therein first receptacle 25 and second receptacle 26 to form first axis locking mechanism 30A. First contoured end 35 and second contoured end 36 of link block 12 preferably releasably couple, lock, or fit together male-to-female with second receptacle 26 of first masonry block 10.1 and first receptacle 25 of second masonry block 10.2 to form first axis locking mechanism 30; thus, to affix, hold, or lock first masonry block 10.1 and second masonry block 10.2 in position or one affixed to another along first axis 30B.

Referring now to FIG. 4 by way of example, and not limitation, there is illustrated exemplary two or more courses of wall W of masonry block 10 of FIG. 1 and link block 12 of FIG. 2 to form second axis locking mechanism 40A.

Second Axis Interlocking Feature

Preferably, one or more masonry block 10.2 and 10.3 are positioned end-to-end to form one or more courses with link block 12 positioned therein to form first axis locking mechanism 30A. Preferably two or more masonry blocks 10 may be stacked one on top of the other, such as masonry block 10.1 stacked on top of masonry block 10.2 and 10.3 to form second axis locking mechanism 40A, wherein top 23 of masonry blocks 10.2 and 10.3 is preferably formed with at least one stepped section having a base that begins with a level footing, such as footer 23.3 and plateau 23.1 (shown in FIG. 1), and bottom 24 of second masonry blocks 10.1 is preferably formed with at least one other matched stepped section having a base that begins with a level footing, such as footer 24.3 and plateau 24.1 (shown in FIG. 1), wherein bottom 24 of second masonry blocks 10.1 is disposed to releasably receive, fit, or match top 23 of masonry block 10.2 and 10.3, respectively, to form second axis locking mechanism 40A throughout wall W, thus, to affix, hold, or lock third masonry blocks 10.1, 10.2, and 10.3 in position or one affixed to another along second axis 40A.

In use, a plurality of masonry blocks 10 form a larger structure laid course by course to form wall W. For example, for each pair of masonry blocks 10 positioned in row N, such pair of masonry blocks 10 may be coupled or interlocked together by inserting link block 12 therebetween in row N forming laid course one next to the other coupled or interlocked together by first axis locking mechanism 30A, to form wall W. Moreover, by overlapping rows of interlocking masonry block 10 to form wall W, foundation wall, retaining wall or the like imparting strength and durability to a wall W of masonry blocks 10 having horizontal plane of interlocks between neighboring horizontal masonry blocks 10 further forming a solid endless row or chain of horizontal blocks coupled or interlocked together by first axis locking mechanism 30A. Moreover, for each pair of masonry blocks 10 positioned in different rows, such as row N and row O, each masonry block 10 may be in contact with up to six (6) other masonry blocks 10, such as masonry block 10.3 may be affixed, coupled, or interlocked in contact with masonry blocks 10.1, 10.2, 10.4, 10.5, 10.6, and 10.7 forming laid courses one next to the other and one on top and under the other, to form wall W a solid endless stack of or staggered blocks affixed, coupled, or interlocked together by second axis locking mechanism 40A.

It is recognized herein that each block is plum and aligned with its neighboring masonry blocks 10 in contact therewith and masonry blocks 10 with first axis locking mechanism 30A and second axis locking mechanism 40A and functions to create a free-standing mortar-less wall W block unit assembled as a plurality of blocks forming a wall W without the need for reinforcement with rods or posts or filled with concrete/grout or both, as shown in FIG. 4. It is further recognized herein that sides 27A and 27B shown in FIG. 1 are approximately ninety degrees relative to wall W first axis 30B, and sides 21 and 22, and parallel to second axis 40A and, preferably maintain masonry blocks 10 in approximately straight alignment as a plurality of blocks forming an approximately straight wall W, as shown in FIG. 4.

It is further contemplated herein masonry blocks 10 and their respective first axis locking mechanism 30A and second axis locking mechanism 40A impart strength and durability to a wall W of masonry blocks 10 having interlocks in two different planes adjacent top to bottom second axis 40B, as well as adjacent side by side first axis 30B, respectively, as shown in FIGS. 3 and 4.

Furthermore, the sides of masonry blocks 10 preferably are formed to include beveled edge 39, as shown in FIG. 1, so that an outward face of a portion of a wall W assembled with the plurality of masonry blocks 10 include the appearance of mortar, cement, or grout-like horizontal and vertically oriented gaps between masonry blocks 10, each one of the plurality of mortar like horizontally or vertically oriented gaps located adjacently between each one of the plurality of masonry blocks 10 without the use of mortar or grout, as shown in FIGS. 3 and 4.

In use, a plurality of masonry blocks 10 may be utilized to form a larger structure laid course by course, one on top of the other, as either staggered in overlapping masonry configuration or aligned to form for example, a foundation wall, retaining wall, incline retaining walls, edging, tree ring, garden planters, sand box, or the like, such as wall W, to impart strength and durability to a wall of masonry blocks 10 having horizontal and vertical planes or multiple axis of interlocks between neighboring masonry blocks 10.

It is recognized herein that first axis locking mechanism 30A and second axis locking mechanism 40A interlock or cooperate together, one block with one or more others, in a wall W assembly configured to maintain each masonry block 10 plum and aligned with its neighboring masonry blocks 10 in contact therewith and functions to create a free-standing mortar-less wall W block unit assembled as a plurality of blocks forming wall W without the need for reinforcement with rods or posts or filled with concrete/grout or both, as shown in FIG. 4.

It is further recognized herein that footer(s) 24.3 shown in FIG. 1 preferably provide masonry blocks 10 with a broader footprint than a sharp transition corners or edges between sides 21/22 to reduce the possibility of cracks and breakage during shipping, handling, and assembly.

It is contemplated that first axis locking mechanism 30A and second axis locking mechanism 40A impart strength and durability to a wall W of masonry blocks having interlocks in two different planes adjacent top to bottom vertical mode as well as adjacent side by side horizontal mode, as shown in FIGS. 3 and 4.

Furthermore, the sides of masonry blocks 10 preferably are formed to include beveled edge 39, shown in FIGS. 1, 3 and 4, to form an outward face of a portion of a wall W assembled with the plurality of masonry blocks 10 to create or include the appearance of mortar, cement, or grout-like horizontal and vertically oriented gaps between masonry blocks 10, each one of the plurality of mortar like horizontally or vertically oriented gaps located adjacently between each one of the plurality of masonry blocks 10 without the use of mortar or grout, as shown in FIGS. 3 and 4.

Referring now to FIG. 5 by way of example, and not limitation, there is illustrated an alternate example masonry article, brick or block and a collection thereof, such as masonry block 10A. Preferably first receptacle 25 and second receptacle 26 are preferably formed as a horseshoe shape female portion, indentation or cylindrical shaped seat (wherein side end 27A/27B and 28A/28B are preferably angle A1 an acute angle, preferably approximately 70 degrees, relative to sides 21 and 22), but other angles and shapes for first receptacle 25 and second receptacle 26 are contemplated herein, which traverse vertically and approximately top to bottom of masonry block 10A, so as to cooperate and interlock with link block 12 between two masonry blocks 10A.

It is recognized herein that side end 27 and 28 are preferably angle A1 an acute angle are preferably configured to enable wall construction in a contour or circular configuration.

Referring now to FIG. 6 by way of example, and not limitation, there is illustrated an example embodiment arcuate, curved, or circular wall W as an assembly of masonry blocks shown in FIG. 5. In use, preferably, one or more masonry block 10A are positioned end-to-end along a curved or contoured line to form one or more courses, where first receptacle 25 of first masonry block 10A.1 is positioned proximate or butted up against second receptacle 26 of second masonry block 10A.2 contoured along first angular axis 30C. Preferably link block 12 is positioned therein first receptacle 25 and second receptacle 26 to form first axis locking mechanism 30A. First contoured end 35 and second contoured end 36 of link block 12 preferably releasably couple, lock, or fit together male-to-female with first receptacle 25 of first masonry block 10A.1 and second receptacle 26 of second masonry block 10A.2 to form first axis locking mechanism 30A; thus, to affix, hold, or lock first masonry block 10A.1 and second masonry block 10A.2 in position or one affixed to another along first angular axis 30C.

Moreover, for each masonry block 10A positioned in different rows, such as row N and row O, each masonry block 10A may be in contact with up to four (4) other masonry blocks 10A, such as masonry block 10A.3 may be affixed, coupled, or interlocked in contact with masonry blocks 10A.1, 10A.2, 10A.4, and 10A.5 to form laid courses one next to the other and one aligned on top and under the other, to form angled, circular, or serpentine wall W a solid endless stack of aligned non-staggered blocks affixed, coupled, or interlocked together by first axis locking mechanism 30A and second axis locking mechanism 40A shown in FIG. 4.

Such non-overlapping rows of interlocking masonry block 10A preferably form curved wall, foundation wall, retaining wall or the like imparting strength and durability to curved wall W of masonry blocks 10A having horizontal and vertical plane of interlocks between neighboring masonry blocks 10A further forming a solid endless chain of curved blocks. It is recognized herein that angle A1 of side end 27A/27B and 28A/28B of masonry blocks 10A are preferably configured to enable first axis locking mechanism 30A to be formed along angle A1 to maintain each masonry block 10A plum and aligned in a continuous arc or curve, such as first angular axis 30C, with its neighboring masonry blocks 10A in contact therewith and functions to create a free-standing mortar-less curved wall W block unit assembled as a plurality of masonry blocks 10A to form curved wall W without the need for reinforcement with rods or posts or filled with concrete/grout or both.

It is contemplated herein that non-overlapping masonry blocks 10A formed by positioning or laying one course on top the other course are preferably utilized herein to form curved or arcing wall W.

It is further contemplated herein that angle A1 an acute angle, preferably approximately 70 degrees, relative to sides 21 and 22 aligned masonry blocks 10A preferably form approximately a forty-eight inch circular wall W or greater, as shown in FIG. 6; thus it is still further contemplated herein that other angles A1 will accommodate other radius and circumference circular walls W.

Referring now to FIG. 7 by way of example, and not limitation, there is illustrated an example corner brick/block, such as masonry block 10B an alternate embodiment of FIG. 1. Preferably second receptacle 26B of masonry block 10B is positioned adjacent one other second end or side, such as side 22 of masonry block 10B. Moreover, first receptacle 25 and second receptacle 26B are preferably formed as a horseshoe shape female portion, indentation, or cylindrical shaped seat (wherein side end 27A and 28A are preferably angle A ninety degrees relative to sides 21 and 22 and wherein side end 27B.1 and 28B are preferably parallel to axis A2 and side 22), but other shapes for first receptacle 25 and second receptacle 26B are contemplated herein, which traverse vertically and approximately top to bottom of masonry block 10B, so as to cooperate and interlock with link block 12 between two masonry blocks 10B.

It is contemplated herein that masonry block 10B may be reversed wherein second receptacle 26B of masonry block 10B may be positioned adjacent side 21 of masonry block 10B.

Referring now to FIG. 8 by way of example, and not limitation, there is illustrated an example joiner/corner brick/block, such as masonry block 11 an alternate embodiment of FIGS. 1, 2, and 7. Preferably second receptacle 26B of masonry block 11 is positioned adjacent one other second end or side, such as side 22 of masonry block 11. Preferably first receptacle 25B of masonry block 11 is positioned adjacent one first end or side, such as side 24 of masonry block 11. Moreover, first receptacle 25B and second receptacle 26B are preferably formed as a horseshoe shape female portion, indentation, or cylindrical shaped seat (wherein side end 27B.1 and 28B are preferably parallel to axis A2 and to side 22 and side end 27A.1 and 28A.1 are preferably parallel to axis A3 and to side 24), but other shapes for first receptacle 25B and second receptacle 26B are contemplated herein, which traverse vertically and approximately top to bottom of masonry block 11, so as to cooperate and interlock with link block 12 between two masonry blocks 11 or between masonry blocks 11 and masonry blocks 10.

Furthermore, contoured nose 25.2 of masonry block 11 is preferably positioned at one first end of masonry block 11 and includes one or more surface or contoured side 25.1 and side end 27A and 28A formed substantially as a horseshoe shaped male portion, protrusion, or contoured or cylindrical shaped nose protrudes from first end (wherein side end 27A and 28A are preferably approximately ninety degrees relative to sides 22 and 24), but other shapes for contoured nose 25.2 are contemplated herein, which traverse vertically and approximately top to bottom of masonry block 11.

It is contemplated herein that masonry block 11 may be reversed wherein second receptacle 26B of masonry block 11 may be positioned within side 21 and first receptacle 25B of masonry block 11 may be reverse positioned within side 22 of masonry block 11.

Referring now to FIG. 9 by way of example, and not limitation, there is illustrated an example embodiment column C having ninety degree walls W of an assembly of masonry blocks shown in FIG. 7, FIG. 8 and FIG. 2. Preferably, a plurality of masonry blocks 10B and masonry blocks 11 are laid course by course in non-overlapping masonry configuration to form cornered wall W. Preferably, combination contoured nose 25.2 of masonry blocks 11 and second receptacle 26B of masonry blocks 10B form male-to-female interlock and first receptacle 25 of masonry blocks 10B and second receptacle 26B of masonry blocks 11 are configured to receive link block 12; and top 23, bottom 24 and their respective footers 23/24 couple or interlock, as shown in FIG. 4, to thereby, impart strength and durability to a column C or cornered wall W of masonry blocks having interlocks in two different planes adjacent top to bottom vertical mode as well as adjacent side by side horizontal mode, such as first axis locking mechanism 30A and second axis locking mechanism 40A, shown in FIG. 4.

In use, preferably contoured nose 25.2 and second receptacle 26B of masonry blocks 10B releasably couple or fit together male-to-female when different masonry blocks 10B and 11 or first receptacle 25 of masonry blocks 10B form male-to-female interlock with second receptacle 26B of masonry blocks 11 configured to receive link block 12) form a larger structure laid course by course to form column C. Such non-overlapping rows of interlocking masonry blocks 10B and/or 11 preferably form column C or the like imparting strength and durability to column C of masonry blocks 10B and/or 11 having horizontal and vertical plane of interlocks between neighboring masonry blocks 10B and/or 11.

It is recognized herein that contoured nose 25.2 of masonry blocks 11 and first receptacle 25 of masonry blocks 10B and second receptacle 26B of masonry blocks 11 configured to receive link block 12 interlock together, one with one or more others, in a wall W assembly configured to maintain each masonry block 11 and masonry block 10B plum and aligned in straight or ninety degree turn with its neighboring masonry blocks 10B and masonry blocks 11 in contact therewith and functions to create a free-standing mortar-less cornered column C block unit assembled as a plurality forming cornered wall W without the need for reinforcement with rods or posts or filled with concrete/grout or both.

Referring now to FIG. 10 by way of example, and not limitation, there is illustrated an alternate example octagonal masonry article, brick or block and a collection thereof, such as masonry block 10C. Preferably first receptacle 25 and second receptacle 26 are preferably formed as a horseshoe shape female portion, indentation or cylindrical shaped seat (wherein side end 27A/27B and 28A/28B are preferably angle A4 an obtuse angle, preferably approximately 135 (360/8=45 degrees or (90+45)=135), relative to side 22), but other angles and shapes for first receptacle 25 and second receptacle 26 are contemplated herein, which traverse vertically and approximately top to bottom of masonry block 10C, so as to cooperate and interlock with link block 12 between two masonry blocks 10C.

It is recognized herein that side end 27 and 28 are preferably angle A4 are an obtuse angle and preferably configured to enable wall W construction in an octagonal wall configuration.

Referring now to FIG. 11 by way of example, and not limitation, there is illustrated an example joiner brick/block, such as an alternate embodiment masonry block 11A, which is similar to FIG. 10. Preferably third receptacle 26B of masonry block 11A positioned adjacent one other second end or side, such as side 22 of masonry block 11A. Moreover, first receptacle 25, second receptacle 26, and third receptacle 26B are preferably formed as a horseshoe shape female portion, indentation, or cylindrical shaped seat (wherein side end 22A and 22B are preferably parallel to sides 22), but other shapes for first receptacle 25, second receptacle 26, and third receptacle 26B are contemplated herein, which traverse vertically and approximately top to bottom of masonry block 11A.

It is contemplated herein that masonry block 11A may be reversed wherein third receptacle 26B of masonry block 11A may be positioned within side 21.

Referring now to FIG. 12 by way of example, and not limitation, there is illustrated an example embodiment octagonal wall W, as an assembly of masonry blocks shown in FIGS. 10 and 11. In use, preferably, one or more masonry blocks 10C and/or one or more masonry blocks 11A are positioned end-to-end along an octagonal, curved, or contoured line, such as first angular axis 30C to form one or more courses, where first receptacle 25 of first masonry block 10C/11A is positioned proximate or butted up against second receptacle 26 of second masonry block 10C/11A and contoured along first angular axis 30C. Preferably link block 12 is positioned therein first receptacle 25 and second receptacle 26 to form first axis locking mechanism 30. First contoured end 35 and second contoured end 36 of link block 12 preferably releasably couple, lock, or fit together male-to-female with first receptacle 25 of first masonry block 10C/11A positioned proximate or butted up against second receptacle 26 of second masonry block 10C/11A to form first axis locking mechanism 30; thus, to affix, hold, or lock first receptacle 25 and second receptacle 26 in position or one affixed to another along first angular axis 30C.

Moreover, for each masonry block 10C/11A positioned in different rows, such as row N and row O, each masonry block 10C/11A may be in contact with up to four (4) other masonry blocks 10C/11A, such as masonry block 10C.3 may be affixed, coupled, or interlocked in contact with masonry blocks 10C.1, 10C.2, 10C.4, and 11A.1 to form laid courses one next to the other and one on top and under the other, to form angled, circular, or serpentine wall W a solid endless stack of aligned non-staggered blocks affixed, coupled, or interlocked together by first axis locking mechanism 30 and second axis locking mechanism 40, shown in FIGS. 3 & 4.

Such non-overlapping rows of interlocking masonry block 10C/11A preferably form octagon, foundation wall, retaining wall, curved wall W or the like imparting strength and durability to curved wall W of masonry blocks 10C/11A having horizontal and vertical plane of interlocks between neighboring masonry blocks 10C/11A further forming a solid endless chain of curved blocks. It is recognized herein that angle A4 of side end 27A/27B and 28A/28B of masonry blocks 10C are preferably configured to enable first axis locking mechanism 30A to be formed along angle A4 to maintain each masonry block 10C/11A plum and aligned in a continuous arc or curve with its neighboring masonry blocks 10C/11A in contact therewith and functions to create a free-standing mortar-less curved wall W block unit assembled as a plurality of masonry blocks 10C/11A to form curved wall W without the need for reinforcement with rods or posts or filled with concrete/grout or both.

It is contemplated herein that non-overlapping masonry blocks 10C/11A formed by positioning or laying one course on top the other course are preferably utilized herein to form octagonal landscaping column C, such as eight sided octagonal landscaping column C to form closed column course.

It is further contemplated herein that masonry block 12 preferably form approximately a twenty-four inch diameter octagonal landscaping column C, as shown in FIG. 12; thus it is still further contemplated herein that other angles A4 will accommodate other radius and circumference octagonal landscaping column C.

Referring now to FIG. 13 by way of example, and not limitation, there is illustrated an example receptacle embodiment of the masonry article, building product, brick or block and a collection thereof, such as masonry block 10D. Preferably, masonry block 10D, or a plurality of blocks thereof, includes front 21, back 22, top 23, and bottom 24, and first receptacle 25 and second receptacle end 26, such masonry block 10D arranged preferably as, a rectangle-like sided structure. It is contemplated herein that configurations other than rectangle-like sides forming preferably receptacle ends and stepped top and bottom structure for masonry block 10D may be utilized herein or others known to one of ordinary skill in the art. Moreover, first receptacle 25 and second receptacle 26 are preferably formed as a horseshoe shape female portion, indentation or cylindrical shaped seat (wherein side end 27 and 28 are preferably angle A approximately ninety degrees relative to sides 21 and 22), but other shapes for first receptacle 25 and second receptacle 26 are contemplated herein, which traverse vertically and approximately top to bottom of masonry block 10D, so as to cooperate and interlock with link block 12 between two masonry blocks 10D.

Moreover masonry blocks 10D may be configured with one or more conduits or channels therethrough, such as passageway 52. Preferably masonry blocks 10D includes passageway 52A and passageway 52B configured as a square conduit; however, other shapes for passageway 52A and passageway 52B are contemplated herein, which traverse vertically and approximately top to bottom of masonry block 10D, so as to reduce the weight of masonry blocks 10D. It is further contemplated herein that passageway 52A and passageway 52B may be tapered from one end to the other.

It is contemplated herein that any of the masonry bricks/blocks disclosed herein may incorporate features and functionality of masonry block 10D of FIG. 13. In use, passageway 52A and passageway 52B of masonry blocks 10D laid course by course may be utilized to run electrical wiring, communication cabling, plumbing and the like.

Referring now to FIG. 14 by way of example, and not limitation, there is illustrated exemplary two or more courses of masonry block 10D of FIG. 13 and link block 12 of FIG. 2 to form first axis locking mechanism 30A and second axis locking mechanism 40A of wall W. In use, a plurality of masonry blocks 10D form a larger structure laid course by course to form wall W. For example, for each pair of masonry blocks 10D positioned in row N, such pair of masonry blocks 10D may be coupled or interlocked together by inserting link block 12 therebetween in row N forming laid course one next to the other, to a course of form wall W. Moreover, by overlapping rows of interlocking masonry block 10D to form wall W, foundation wall, retaining wall or the like imparts strength and durability to a wall W of masonry blocks 10D having horizontal plane of interlocks between neighboring horizontal masonry blocks 10D.1 and 10D.2 further forming a solid endless chain of horizontal blocks coupled or interlocked together by first axis locking mechanism 30A. Moreover, for each pair of masonry blocks 10D positioned in different rows, such as row N and row O, each masonry block 10D may be in contact with up to six (6) other masonry blocks 10D, to form wall W a solid endless stack of or staggered blocks affixed, coupled, or interlocked together by second axis locking mechanism 40A.

It is recognized herein that each block is plum and aligned with its neighboring masonry blocks 10D in contact therewith and masonry blocks 10D with first axis locking mechanism 30A and second axis locking mechanism 40A and functions to create a free-standing mortar-less wall W block unit assembled as a plurality of blocks forming a wall W without the need for reinforcement with rods or posts or filled with concrete/grout or both.

It is further contemplated herein masonry blocks 10D and their respective first axis locking mechanism 30A and second axis locking mechanism 40A impart strength and durability to a wall W of masonry blocks having interlocks in two different planes adjacent top to bottom second axis 40A, as well as adjacent side by side first axis 30A, respectively, as shown in FIGS. 3 and 4.

Referring now to FIG. 15 by way of example, and not limitation, there is illustrated an alternate example masonry article, brick or block and a collection thereof, such as masonry block 10E. Preferably first receptacle 25 and second receptacle 26 are preferably formed as a horseshoe shape female portion, indentation or cylindrical shaped seat (wherein side end 27A/27B and 28A/28B are preferably angle A1 an acute angle, preferably approximately 70 degrees, relative to sides 21 and 22), but other angles and shapes for first receptacle 25 and second receptacle 26 are contemplated herein, which traverse vertically and approximately top to bottom of masonry block 10E, so as to cooperate and interlock with link block 12 between two masonry blocks 10E.

It is recognized herein that side end 27 and 28 are preferably angle A1 an acute angle are preferably configured to enable wall W construction in an arcuate, contour, or circular wall configuration.

Referring now to FIG. 16 by way of example, and not limitation, there is illustrated an example embodiment arcuate, curved, or contoured wall W as an assembly of masonry blocks shown in FIG. 15. In use, preferably, one or more masonry block 10E are positioned end-to-end along a curved or contoured line to form one or more courses, where first receptacle 25 of first masonry block 10E.1 is positioned proximate or butted up against second receptacle 26 of second masonry block 10E.2 contoured along first angular axis 30C. Preferably link block 12 is positioned therein first receptacle 25 and second receptacle 26 to form first axis locking mechanism 30A. First contoured end 35 and second contoured end 36 of link block 12 preferably releasably couple, lock, or fit together male-to-female with first receptacle 25 of first masonry block 10E.1 and second receptacle 26 of second masonry block 10E.2 to form first axis locking mechanism 30A; thus, to affix, hold, or lock first masonry block 10E.1 and second masonry block 10E.2 in position or one affixed to another along first angular axis 30C.

Moreover, for each masonry block 10E positioned in different rows, such as row N and row O, each masonry block 10E may be in contact with up to four (4) other masonry blocks 10E, such as masonry block 10E.3 may be affixed, coupled, or interlocked in contact with masonry blocks 10E.1, 10E.2, 10E.4, and 10E.5 to form laid courses one next to the other and one on top and under the other, to form angled, arcuate, circular, or serpentine wall W, a solid endless stack of aligned non-staggered blocks affixed, coupled, or interlocked together by first axis locking mechanism 30A and second axis locking mechanism 40A.

Such non-overlapping rows of interlocking masonry block 10E preferably form curved wall W, foundation wall, retaining wall or the like imparting strength and durability to curved wall W of masonry blocks 10E having horizontal and vertical plane of interlocks between neighboring masonry blocks 10E further forming a solid endless chain of curved blocks. It is recognized herein that angle A1 of side end 27A/27B and 28A/28B of masonry blocks 10E are preferably configured to enable first axis locking mechanism 30A to be formed along angle A1 to maintain each masonry block 10E plum and aligned in a continuous arc or curve with its neighboring masonry blocks 10E in contact therewith and functions to create a free-standing mortar-less curved wall W block unit assembled as a plurality of masonry blocks 10E to form curved wall W without the need for reinforcement with rods or posts or filled with concrete/grout or both.

It is contemplated herein that non-overlapping masonry blocks 10E formed by positioning or laying one course on top the other course are preferably utilized herein to form curved or arcuate wall W.

It is recognized herein that sides 21 and 22 are preferably eight inches in height to form a standard block configuration, but other sizes for masonry block 10E are contemplated herein.

It is contemplated herein that masonry block may be utilized to construct landscaping column C and straight or curved walls W, wherein masonry block laid one next to the other and one course on another course without the need for reinforcement with rods or posts or filled with concrete/grout or both imparting strength and durability to wall W of masonry blocks having interlocks in two different planes.

It is recognized herein that do-it-yourself and home owner projects of wall W construction may be achieved utilizing masonry block without the need of a skilled brick layer, mortar, or site concrete/grout mixing equipment.

It is contemplated herein that each masonry block is preferably locked into wall W from four or more sides creating interlocks there between in two different planes.

It is contemplated herein that masonry blocks may be bonded together using glue or other adhesive on both ends and the top and bottom to increase the strength of wall W. Moreover, a clamp, tie or strap may be used to wrap around a group of assembled masonry block and tighten such strapping enables the adhesive to set forming increased strength wall W of masonry blocks with interlocks in two different planes.

It is contemplated herein that masonry blocks may be provided without beveled edge 39 in order to provide smooth construction, more specifically no simulated grout or concrete lines added to wall W.

It is contemplated herein that any of the masonry blocks shown herein may have any of the features set forth herein integrated into the masonry block.

Referring now to FIG. 17, there is illustrated a flow diagram 1700 a method of forming at least a portion of a wall of masonry articles having interlocks in two different planes configured with two or more courses. In block or step 1710, providing two or more masonry blocks 10/11 includes providing blocks 10/11 configured with front side 21 and opposed back side 22, a first end, first receptacle 25 and a second end, second receptacle 26 extend from front side 21 to back side 22, wherein first receptacle 25 and a second end, second receptacle 26 are each configured with a contour receptacle portion therein, a first load bearing, such as top 23 and a second opposed load bearing surface, such as bottom 24 extend, parallel to and match one another from front side 21 to back side 22, and extend from first receptacle 25 to second receptacle 26, wherein top 23 configured with one or more tiered sub-surfaces and bottom 24 configured with one or more tiered sub-surfaces to releasably couple one top 23, link block 12 configured with front contoured divot 31 and back contoured divot 32, first contoured end 35 and second contoured end 36 extend from said front contoured divot 31 to back contoured divot 32. In block or step 1720, assembling first course of masonry articles wherein two or more masonry blocks 10/11 configured butted end to end and releasably coupled by link block 12 to form first axis locking mechanism 30A. In block or step 1730, assembling a second course of masonry articles, second course on top of the other in first course, wherein the surfaces of two or more the masonry articles, such as top 23 and bottom 24 of masonry blocks 10/11 and the surfaces of each masonry block interlock mating one masonry article to another to form first axis locking mechanism 40A.

The foregoing description and drawings comprise illustrative embodiments of the present invention. Having thus described exemplary embodiments, it should be noted by those ordinarily skilled in the art that the disclosures within are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments of the invention will come to mind to one ordinarily skilled in the art to which this invention pertains, having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Moreover, the present invention has been described in detail; it should be understood that various changes, substitutions and alterations can be made thereto without departing from the spirit and scope of the invention as defined by the appended claims. Accordingly, the present invention is not limited to the specific embodiments illustrated herein, but is limited only by the following claims.

	Number	Date	Country
Parent	13370516	Feb 2012	US
Child	13673383		US

MASONRY BLOCK, LINK, AND METHOD OF INTERLOCKING

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CPC

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Abstract

Description

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CROSS REFERENCE TO RELATED APPLICATIONS

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