1. Field of the Invention
The present invention relates to blocks which are conventionally employed to build privacy and retaining walls. More particularly, the device herein disclosed relates to a block system which allows the user to employ only two types of block to build any wall and optionally three types. The system employs a full sized block having a novel “H” shape. An entire wall may be formed of this single block.
The unique “H” shaped block and “C” shaped block allow the user to build a wall with a high degree of sheer strength through the provision of projecting pins which engage with overhead blocks in the formed wall. Additional strength in the formed wall may be provided through interweaving vertical metal reinforcing bars which communicate through the levels of engaged blocks. When used in combination with such reinforcing bars, the device and method herein disclosed yields great utility by allowing the reinforcing bars and blocks to be interfaced without the need to lift the heavy blocks over the top of distal end of the metal bar as is conventionally done. Walls with reinforcing bars can thus be built quicker and with less exertion and injuries to the workers building. Employing the embodiments of the blocks herein described and disclosed, the endwalls of the blocks used are open and allow the blocks to simply be angled around the reinforcing bar and engaged with each other with formed pins which project above the top surface of each block and engage with cavities in the bottom of overriding blocks. Projecting endwall tongue and groove engagement is also provided for an extremely strong engagement of all the blocks forming any one wall. The resulting wall is built in less time and provides resistance to earthquakes and other lateral forces which might cause failure in walls lacking the structural integrity provided by the interlocking system of pins and cavities and allowance for easy use of reinforcing bar.
2. Prior Art
The building of walls goes back to ancient times when rocks were used. Modern wall building conventionally employs blocks to build decorative and retaining and privacy walls. Conventional techniques, especially where the wall is to retain soil from subsidence or provide a building foundation, use blocks with closed cavities, smooth endwalls, and generally planar upper and lower surfaces. The blocks are stacked upon each other with each subsequent layer of blocks overlapping the underlying seams between individual blocks. Because of the smooth surfaces of the blocks, they rely upon the mortar, grout or cement to hold them in engagement to each other. To insure that this engagement is permanent and to provide additional strength against lateral forces and earthquake type forces, most conventional block walls employ vertical steel rods and on many types of construction, horizontal steel rods which communicate to adjacent blocks. The steel reinforcement rods must be threaded through closed cavities of conventional blocks used, and once all the blocks and steel are properly placed, mortar, grout or similiar cement-like material is then filled into the closed cavities. The cementitious material, once dried, will lock the metal bars and the blocks in a fixed engagement with each other.
As is well known, the requirement of placing blocks adjacent to each other in proper spacing to form a layer and repeating the process with each overhead layer supported by underlying layers is tedious. Further, it requires a great expenditure in time and energy on the part of workers, and because of the nuances of engaging adjacent blocks and interwoven steel rods with sufficient cement mortar or grout, block formed walls require a lot of worker skill to complete successfully and aesthetically. This is especially true when reinforcing bars are employed and interwoven between lower brick layers and those above them. Not only must the metal bars be properly placed and interwoven as the wall is built upward, the blocks themselves must be lifted upward above the distal high end of the vertical reinforcing bars, and once there, they must be lowered with the reinforcing bar threaded into the internal cavities of the block. With each block weighing between 28 to 36 pounds, this is a daunting and exhausting task for even the most experienced block builder.
Further, typical conventional concrete blocks have smooth side surfaces and generally planar top and bottom surfaces on which the blocks engage underlying or overlying block layers in a wall. Such construction provides no means to interlock overhead blocks to underlying layers of blocks in the wall. Conventional concrete blocks generally offer no endwall means of engagement to adjacent blocks in a given layer either. Instead, conventional concrete blocks are designed to be aligned in individual layers of adjacent blocks with subsequent layers formed in the same fashion stacked on top of each other. The grout or mortar must be properly mixed and then expertly applied to each individual block surface that engages an adjacent surface to insure that all blocks in all layers remain engaged by the dried mortar. Of course the application of mortar to the exterior of the individual blocks and through channels formed in the wall only occurs once each block in the wall has been raised over the distal end of the vertical metal reinforcing rods and then held while they are slid down the reinforcing bar to their intended place. Not only must the worker use energy to raise the block up and over the metal bars, the worker then must use additional energy to resist gravity's pull on the block while it is lowered to its proper position. Dropped blocks can cause severe damage to already mortared underlying layers as well as to the dropped block itself. Once so lowered, the individual blocks must be coated with mortar which is allowed to dry before the blocks of the different layers are held in place by the dried cement or mortar or similar cement-like material. If the mortar is improperly mixed or applied, the resulting wall will eventually fail due to slippage of the blocks. Consequently, the skill level for a journeyman block wall mason using conventional blocks in a fashion that will yield a wall with the intended strength and look is fairly high and beyond the scope of most inexperienced workers, homeowners, and uneducated workers in third world countries. While the lack of skill may not dissuade such workers from building walls, the resulting construction can easily be sub-standard and fail, resulting in great property loss and worse yet, loss of life.
Still further, a common complaint with interlocking block styles is that because they interlock, the wall as built is not easily adjustable for length. Non-interlocking blocks in the hands of a good mason may be laid apart and separated by mortar at varying distances to either stretch or shrink the resulting wall. However, interlocking blocks generally must interlock with adjacent blocks above and below at very specific points and are not adjustable.
As such, there exists a continuing unmet need for a block system which will provide for easy building of high-strength walls by both low-skilled and highly skilled workers. Such a device and method should provide a strong wall with excellent lateral support against slippage by adjoining, overhead, and underlying blocks. Such a device and system should provide for engagement of metal reinforcing rods vertically through all the layers of the block wall and should eliminate the need to lift the heavy blocks and then restrain them as they slide over the vertical elongated steel reinforcing bars. Further, such a device and system should provide a means to interlock adjacent blocks on the same level of the wall to provide additional shear strength to the wall once build. Still further, such a device and method should be simple and have as few parts to the block building system as possible to allow for use by unskilled, uneducated workers, and to minimize the number of types of blocks that must be shipped to a building site. Finally, such a device and method of building thereby provided should allow for adjustment of the spacing of adjacent blocks on each layer during construction by allowing for a locked engagement with adjustment through horizontal translation of individual blocks while continuing to provide overhead interlocking. This adjustment provision the builder to shrink or stretch the length of the wall by a few inches depending on how the blocks are engaged, yet still provides a positive interlock of the distal ends and the interior of the sidewalls of the blocks in the wall. This adjustability along with the use of only one block style, if desired, allows for the use of unskilled workers to build high strength and visually pleasing walls even if they make errors in actual placement and engagement to adjacent blocks and overhead and underlying layers.
The device herein disclosed provides concrete blocks for construction of walls using a single block design or two or more block designs that provide for an especially easy method to construct a sturdy wall. The device in all modes employs an “H” shaped first block design which incorporates a number of interlocking features that improve strength and stability of walls and structures. The block also incorporates a double open-end design which eliminates the endwalls required by conventional rectangular blocks. This provision of open endwalls allows for improved vertical metal reinforcing rod engagement between layers of blocks forming the wall without the need to lift and slowly lower the heavy blocks on the upright metal rods. Instead, the blocks are simply angled to allow the open ends to slide around the upright metal rods, thereby reducing the time and effort and number of laborers required to build a wall of great strength. The block may then be locked into place with cooperating projections and receiving cavities of the other adjacent and lower interlocking blocks with the re-bar in the proper location in the block cavity.
Further, the double open-end design allows for improved grout or mortar flow around reinforcing steel and block cavity filling, thereby allowing a higher number of levels or layers of the blocks to be operatively engaged with each other and subsequently internally grouted from above through formed channels for the mortar or grout to flow.
In all embodiments of the device, be it the single block system or employing a second block for aesthetic purposes, the tapered vertical interlocking pins and cooperative engagements for the pins in adjacent overhead blocks allow for tolerances during the building process which provide for longitudinal adjustment of up to ⅛ inch per block. This provides a means adjustment of the final length of the wall as-built and provides a remedy in case of any errors in placement of a block in a layer forming the wall.
Still further, the H-Block design provides a “re-bar chase” or bond beam recess which is pressed into the middle web of the block. The recess provides for additional easy reinforcement of the wall by allowing the placement of horizontal reinforcing metal rods which run through adjacent blocks on a single layer. Using the unique open-ended blocks and included means for adjustment of placement and interlocking components of all the blocks, experimentation has shown a building rate of up to ten times faster for laying the H-block than a conventional mortared block due to the elimination of the need to place the block over the reinforcing steel. Additionally, the workers can be of minimal skill and education since the blocks interlock with each other, and in the simplest mode of the device there is only one block style used.
Because the blocks are manufactured of conventional materials in conventional sizes, manufacturing of the blocks is accomplished in the same manner as for conventional blocks and uses the same types of machines. This allows the device and method to be easily and inexpensively integrated into current manufacturing plants.
With respect to the above description, before explaining at least one preferred embodiment of the herein disclosed invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangement of the components in the following description or illustrated in the drawings. The invention herein described is capable of other embodiments and of being practiced and carried out in various ways which will be obvious to those skilled in the art. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for designing of other structures, methods and systems for carrying out the several purposes of the present disclosed device. It is important, therefore, that the claims be regarded as including such equivalent construction and methodology insofar as they do not depart from the spirit and scope of the present invention.
It is an object of this invention to provide a block building system that requires only one type of block thereby minimizing the number and type of blocks that must be shipped and assembled into a wall.
It is another object of this invention to provide such a block building system that provides interlocking engagements to blocks on adjacent sides in a layer of blocks and with blocks in layers above and below each block in the wall.
It is a further objection of this invention to provide such a block building system that allows for the use of vertical metal reinforcing bars and eliminates the need to raise the blocks to high levels and hold them against gravity while they descend, when incorporating such steel reinforcing bars between layers of a wall.
It is a further object of this invention to provide blocks that may easily be assembled into a wall with exceptional shear strength by unskilled workers.
Yet an additional object of this invention is the provision of an interlocking block system for wall construction that provides for adjustment of the spacing between blocks on any one layer with adjacent blocks to provide means of adjustment of the length of the spacing and ultimate all length.
Further objects of the invention will be brought out in the following part of the specification, wherein detailed description is for the purpose of fully disclosing the invention without placing limitations thereon.
As shown in
When employed as a one block method or system, the primary block 12, on a retaining wall can have its opposing open ends 16, at both termination points at the sides of the wall, filled with mortar or concrete or simply left open and filled with adjacent soil if the wall 14 is a retaining wall. Or when employed as a one block system to build a building, the primary block 12 will function as a corner block 18 to provide interlocking corners to the walls on every other layer of blocks forming the building walls. As noted in this specification, half blocks 19 or specially configured secondary blocks 21 might be employed as an option to yield more aesthetically pleasing results on a straight wall such as shown in
The primary block 12 incorporates a number of means for interlocking with adjacent primary blocks 12 or secondary blocks if employed, which improve both the strength and stability of walls 14 and structures formed of one wall or engaged to adjoining walls 14. At both ends of the primary block 12 are open ends 16 exposing first and second internal cavities 20. As depicted in
Once positioned on a layer 26 in the wall 14, the primary block 12 or the second block when optionally employed may then be secured in an interlocking engagement with blocks in adjacent underlying layers 26, and with primary blocks 12 in adjacent positions on the same layer 26, using one or more means for interlocked engagement.
A first means for interlocked engagement is provided for interlocking all of the primary blocks 12 on an individual layer 26 with adjacent coplanar primary blocks 12. This interlocked engagement is provided by interlocking of the pairs of distal ends 28 of the sidewalls 30 of adjacently located primary blocks 12. Means for interlocking the distal ends 28 with the distal ends 28 of adjacently located coplanar primary blocks 12, in the current favored mode of the device 10, employ a projection 32 adapted for engagement in a recess 34 on the matching distal end the adjacent primary blocks 12. This tongue and groove style engagement shown on distal ends in
Also in the preferred mode of the device 10 all of the primary blocks 12 are provided a means for interlocking primary blocks 12 on one layer 26 to adjacent primary blocks 12 in layers 26 above and below any primary block 12 in any layer 26. The only layer 26 not engaged to primary blocks 12 below it would be the first or lowest layer 26 in the wall 14, since there are no interlocking pins 36 below it on other blocks 12. However, if the wall 14 is constructed on a foundation of cement or other planar foundation, the pins 36 can be formed in that foundation top surface, providing an excellent engagement of the bottom layer to its underlying foundation.
In the current favored mode of the device 10 the means for interlocking primary blocks 12 on a lower layer 26 with any adjacent primary block on an overhead layer 26 is provided by interlocking pins 36 which project above the substantially planar top surface 38 of the primary blocks 12. As shown in
A first side surface 39 of the pins 36 adjacent to the top surface 38 of the block 12 substantially coplanar with the inner surface 41 of the sidewall 30 from which the pin 36 extends above the top surface. It is thus adapted for a frictional engagement on the inner surface 41 on an overhead coplanar primary blocks 12 located with distal ends substantially centered on the underlying block 12.
A second side surface 44 traverse to the first side surface 39 of the pins 36 is adapted for engagement against, or spaced from, the side edges 35 of the shoulders 40 of the overhead primary blocks 12. This provides two means of engagement of the lower primary blocks 12 with those above.
In a particularly preferred mode of the device 10, the distal end of the pins 36 would taper from their center axis to their side edges to provide a tapered point 45 to provide a means for self alignment of primary blocks 12 on higher layers 26 with those on lower layers when laid thereon. Of course the blocks 12 structurally will be the same with or without the points 45 so they could be made without them and such is anticipated.
A second side surface 44 of the pins is adapted for engagement on, or space by a gap 43 from, a respective side edge 35 of the shoulders 40. The side edges 40 of the shoulders are spaced a distance substantially equidistant from the center of the block 12. This distance “D” is slightly more than the distance from the opposing side surfaces 44 of two blocks 12 engaged fully at their distal ends 28 providing a slight gap 43 between one or both of the side surfaces 44 and the side edges 35 when the distal ends are fully engaged. This gap 43 provides a means for allowance of the spacing between adjacent blocks 12 from each other from a maximum spacing where there is no gap 43 to a minimum spacing where the gap 43 would be its greatest from one or both side surfaces and side edges 35. Adjustment of the spacing, and therefore the wall length, may be achieved by changing the spacing of the sliding engagement of the distal ends 28 of the blocks 12 during the layering building process. Currently the maximum gap 43 is about ⅛ of an inch providing up to that much adjustment of block spacing at each engagement of distal ends 28. However, other maximums might be employed and are anticipated. Of course the distal ends 28 of each adjacent block 12 remain fully engaged with the projection 32 and recess 34 since they will slide in their engagement to allow the adjustment. With such a longitudinal adjustment of up to ⅛ inch in the current preferred mode of the device 10, this would allow for an inch adjustment for every eight blocks 12 engaged in a layer of a wall 14 and thus an adjustment of the length of the formed wall 14 even through all the blocks 12 in the wall 12 would still remain interlocked. With the first side surface 39 of all pins 36 engaged against the inner surface 41 of all overhead blocks 12, there is still great shear strength imparted to the formed wall 14 even with the gap 43 on one or both engagements of the second side surface 41 with the shoulders 40. Further, if mortar is employed to fill the wall, the gaps 43 will later be filled locking the second side surface 44 in its position against, or spaced from, the shoulder 40.
As such, in the preferred mode of the device 10 the primary blocks have a plurality of the pins 36 projecting above their respective top surfaces 38 adapted for engagement against the inside surfaces 41 of above mounted blocks 12 and a spaced engagement both shoulders 40 providing means for lateral translation of the blocks 12 in their engagement at their distal ends 24 to adjust wall length and fitment of the blocks 12 with each other. Using the slidable projections 32 engaged into recesses 34, all of the distal ends 28 of the sidewalls 30 are also engaged and will also allow for a translation back and forth in that engagement.
Additionally provided another especially preferred mode of the device 10 may be a means for communicating reinforcing bar 22 vertically through adjacent horizontal layers 26 formed of the primary blocks 12. The current preferred mode of providing the means for communicating reinforcing bar 22 through the layers is provided by adapting the internal cavities 20 of the individual primary blocks 12 for alignment with those of other layers. The internal cavity of lower layered blocks 12 aligns with a portions of the internal cavities 20 of above situated blocks 12 no matter what layer 26 they are located upon. This adaption for alignment provides a path 46 for reinforcing bar 22 through the layers 26, and also forms a channel 48 communicating between blocks 12 on adjacent layers 26 through which mortar or other cementitious material deposited into an upper layer 26 of the wall 14 will communicate into lower layers 26.
Still further, in an especially preferred mode of the device 10 using the primary blocks 12, there is provided a means to horizontally route reinforcing bar 22 through a “re-bar chase” or bond beam recess 50 which is formed into the middle portion 31 of the primary block 12 to form a horizontal channel 52 communicating through all engaged adjacent blocks 12 in the layers 26 of engaged primary blocks 12. Using this channel 52 the wall 14 formed may be reinforced with reinforcing bar 22 horizontally for greater strength.
With respect to the above description, before explaining at least one preferred embodiment of the herein disclosed invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangement of the components in the following description or illustrated in the drawings. The invention herein described is capable of other embodiments and of being practiced and carried out in various ways which will be obvious to those skilled in the art. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
While all of the fundamental characteristics and features of the open ended blocks with interlocking edges have been shown and described herein with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure, and it will be apparent that in some instances some features of the invention may be employed without a corresponding use of other features without departing from the scope of the invention as set forth. It should also be understood that various substitutions, modifications, and variations may be made by those skilled in the art without departing from the spirit or scope of the invention. Consequently, all such modifications and variations and substitutions are included within the scope of the invention as defined by the following claims.
Number | Date | Country | |
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60703636 | Jul 2005 | US |