Modular construction block

Abstract

A modular construction block comprises a masonry block shell including first and second opposing side walls, and an intermediate cross-web formed between the side walls. Each of the first and second side walls comprises first and second opposing end edges, a relatively thin wall section extending from the cross-web to the first end edge, and a relatively thick wall section extending from the cross-web to the second end edge. The relatively thick wall section of each side wall tapers from the cross-web toward the second end edge of the side wall.

Claims

1. A modular construction block, comprising: a masonry block shell having a top and bottom, first and second opposing side walls, and a knock-out end wall formed between said side walls; said knock-out end wall defining a plurality of spaced apart parallel score lines, each score line forming a point of relative structural weakness, such that said knock-out end wall is adapted for being broken away from said construction block after its manufacture and prior to installation, and wherein each score line extends substantially continuously from a top edge of said end wall to a bottom edge of said end wall; and an intermediate cross-web extending continuously between said side walls and continuously from the top of said block shell to the bottom of said block shell, and wherein said cross-web has first and second exposed ends, a thickness, and a height, the height extending from the first exposed end to the second exposed end, and wherein the thickness of said cross-web is substantially uniform along more than 80% of its height from the first exposed end towards the second exposed end, and is greater at the second exposed end along less than 20% of its height, such that the increased thickness at the second exposed end defines a hand hold for lifting and placing said construction block; each of said first and second side walls comprising first and second opposing planar end edges, a thin wall section extending from said cross-web to the first end edge, and a thick wall section extending from said cross-web to the second end edge, said thin wall section being thinner than said thick wall section along substantially an entire length of said thick wall section preceding the second end edge; and the thick wall section of each side wall tapering from said cross-web toward the second end edge of said side wall.

2. A modular construction block according to claim 1, wherein one of said plurality of score lines is formed substantially at a center point of said knock-out end wall.

3. A modular construction block according to claim 1, wherein said knock-out end wall comprises at least three spaced apart parallel score lines.

4. A modular construction block according to claim 1, wherein said knock-out end wall has a thickness, and each score line having a depth greater than 40% of the thickness of said end wall.

5. A modular construction block according to claim 1, wherein two of said score lines are formed adjacent respective end edges of said first and second side walls.

6. A modular construction block according to claim 5, wherein a third score line is formed substantially at a center point of said knock-out end wall.

7. A modular construction block according to claim 1, wherein each of said plurality of score lines is substantially V-shaped.

8. A modular construction block according to claim 1, wherein each of said plurality of score lines has a substantially uniform depth from the top edge of said end wall to the bottom edge of said end wall.

9. A modular construction block according to claim 1, wherein said plurality of score lines are formed located on an exposed outside surface of said knock-out end wall.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Exemplary embodiments of the present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:

(2) FIG. 1 is a perspective view of a modular masonry construction block according to one exemplary embodiment of the present disclosure;

(3) FIG. 2 is a cross-sectional view of the exemplary block taken substantially along line 2-2 of FIG. 1;

(4) FIG. 3 is a further perspective view of the exemplary block

(5) FIG. 4 is a plan view of the exemplary block;

(6) FIG. 5 is a further cross-sectional view of the exemplary block;

(7) FIGS. 6 and 7 are views of the present block with exemplary dimensions labeled;

(8) FIG. 8 is a view showing a partially constructed vertical wall comprising an assembly of exemplary blocks;

(9) FIG. 9 is a perspective view of a modular masonry construction block according to an alternative exemplary embodiment of the present disclosure;

(10) FIG. 10 is a cross-sectional view of the exemplary block taken substantially along line 10-10 of FIG. 9;

(11) FIG. 11 is a further perspective view of the exemplary block

(12) FIG. 12 is a plan view of the exemplary block;

(13) FIG. 13 is a further cross-sectional view of the exemplary block;

(14) FIGS. 14 and 15 are views of the alternative construction block with exemplary dimensions labeled;

(15) FIGS. 16, 17, and 18 are sequential views demonstrating one process for separating the knock-out end wall from the exemplary construction block;

(16) FIG. 19 is a view showing a partially constructed vertical wall comprising an assembly of present blocks.

DESCRIPTION OF EXEMPLARY EMBODIMENTS AND BEST MODE

(17) The present invention is described more fully hereinafter with reference to the accompanying drawings, in which one or more exemplary embodiments of the invention are shown. Like numbers used herein refer to like elements throughout. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be operative, enabling, and complete. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present invention.

(18) Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Unless otherwise expressly defined herein, such terms are intended to be given their broad ordinary and customary meaning not inconsistent with that applicable in the relevant industry and without restriction to any specific embodiment hereinafter described. As used herein, the article “a” is intended to include one or more items. Where only one item is intended, the term “one”, “single”, or similar language is used. When used herein to join a list of items, the term “or” denotes at least one of the items, but does not exclude a plurality of items of the list.

(19) For exemplary methods or processes of the invention, the sequence and/or arrangement of steps described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal arrangement, the steps of any such processes or methods are not limited to being carried out in any particular sequence or arrangement, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and arrangements while still falling within the scope of the present invention.

(20) Additionally, any references to advantages, benefits, unexpected results, or operability of the present invention are not intended as an affirmation that the invention has been previously reduced to practice or that any testing has been performed. Likewise, unless stated otherwise, use of verbs in the past tense (present perfect or preterit) is not intended to indicate or imply that the invention has been previously reduced to practice or that any testing has been performed.

(21) Referring now specifically to the drawings, exemplary embodiments of the present disclosure comprise a modular construction block adapted for assembly with a number of other blocks in a vertical wall or other structure. Exemplary construction block 10 is illustrated in FIGS. 1-8. The construction block (or “A-block”) 10 comprises a masonry block shell having identical opposing (mirrored) side walls 11, 12, an end wall 13, and an intermediate cross-web 14. The end wall 13 and cross-web 14 are integrally formed with the opposing side walls 11, 12, and cooperate with the side walls 11, 12 to define a hollow core 15. The block core 15 is designed for receiving grout, foam insulation, vertical rebar and/or other reinforcement (not shown). In the exemplary embodiment, each of the side walls 11, 12 has first and second opposing end edges 21, 22, a relatively thin wall section 23 extending from the cross-web 14 to the first end edge 21, and a relatively thick wall 24 section extending from the cross-web 14 to the second end edge 22. As best shown in FIG. 4, the relatively thick wall section 24 of each side wall 11, 12 tapers (narrows) from the cross-web 14 toward the second end edge 22. The side walls 11, 12 define respective planar side faces 11A, 12A, or “face shells”. The end wall 13 is formed with respective end edges 21 of side walls 11, 12 and defines a planar end face 13A, or “end shell”.

(22) Referring to FIGS. 2, 4, and 5, the intermediate cross-web 14 of construction block 10 has first and second exposed ends 31, 32, a thickness “t1” and “t2”, and a height “h”. The height “h” extends from the first exposed end 31 to the second exposed end 32. The thickness “t1” of the cross-web at the first exposed end 31 is less than a thickness “t3” of the relatively thin wall section 23 of each side wall 11, 12, and is substantially uniform along more than 80% of the cross-web height “h” from the first exposed end 31 towards the second exposed end 32. The thickness “t2” of the cross-web 14 at its second exposed end 32 is greater than the thickness “t1” at its first exposed end 31, and is thicker along less than 20% of the cross-web height “h” such that the increased thickness defines a hand hold 35 for lifting and placing the construction block 10. As best shown in FIGS. 4 and 5, the cross-web 14 extends from a top of the block 10 to a bottom of the block 10, and has a relatively uniform cross-sectional thickness from the first side wall 11 to the second side wall 12.

(23) FIGS. 6 and 7 disclose one exemplary embodiment of the present wall block 10 with dimensions provided in inches. The numerical dimensions serve to establish the relative size, shape, and thickness of various structural parts and features, and are included only for purposes of exemplary illustration. A partial vertical wall “W” constructed using an assembly of the present modular blocks 10 is illustrated in FIG. 8.

(24) A further exemplary embodiment of the present disclosure is illustrated in FIGS. 9-15. Construction block 100 comprises a masonry block shell having identical opposing (mirrored) side walls 111, 112, a knock-out end wall 113, and an intermediate cross-web 114. The end wall 113 and cross-web 114 are integrally formed with the opposing side walls 111, 112, and cooperate with the side walls to define a hollow core 115. Like block 10, each of the side walls 111, 112 has first and second opposing end edges 121, 122, a relatively thin wall section 123 extending from the cross-web 114 to the first end edge 121, and a relatively thick wall section 124 extending from the cross-web 114 to the second end edge 122. As best shown in FIG. 11, the relatively thick wall section 124 of each side wall 111, 112 tapers (narrows) from the cross-web 114 toward the second end edge 122. The side walls 111, 112 define respective planar side faces 111A, 112A (or “face shells”), while the end wall 113 defines a vertically scored end face 113A (or “end shell”).

(25) Like block 10, the intermediate cross-web 114 of construction block 100 has first and second exposed ends 131, 132, a thickness “t1” and “t2”, and a height “h”. The height “h” extends from the first exposed end 131 to the second exposed end 132. The thickness “t1” of the cross-web 114 at the first exposed end 131 is less than a thickness “t3” of the relatively thin wall section 123 of each side wall 111, 112, and is substantially uniform along more than 80% of the cross-web height “h” from the first exposed end 131 towards the second exposed end 132. The thickness “t2” of the cross-web 114 at its second exposed end 132 is greater than the thickness “t1” at its first exposed end 131, and is thicker along less than 20% of the cross-web height “h” such that the increased thickness defines a hand hold 135 for lifting and placing the construction block 100. As best shown in FIGS. 11 and 13, the cross-web 114 extends from a top of the block 100 to a bottom of the block 100, and has a relatively uniform cross-sectional thickness from the first side wall 111 to the second side wall 112.

(26) Referring to FIGS. 11, 12, and 13, the knock-out end wall 113 of the exemplary block 100 includes an number of spaced-apart parallel score lines 141, 142, and 143 extending vertically and substantially continuously from a top edge of the end wall 113 to a bottom edge of the end wall 113. Two of the score lines 141, 142 are formed adjacent respective end edges 121 of the first and second side walls 111, 112, while the third score line 143 is formed substantially at a center point of the end wall 113. In one embodiment, the exemplary score lines 141-143 are substantially V-shaped, and have a substantially uniform depth “d” from the top edge of the end wall 113 to the bottom edge of the end wall 113. The score depth “d” may be greater (or deeper) than 40% of the thickness “t4” of the end wall 113. The score lines 141-143 form respective points of relative structural weakness, such that the knock-out end wall 113 may optionally be broken away from the construction block 100 after its manufacture and prior to installation.

(27) FIGS. 14 and 15 disclose one exemplary embodiment of the wall block 100 with dimensions provided in inches. The numerical dimensions serve to establish the relative size, shape, and thickness of various structural parts and features, and are included only for purposes of exemplary illustration.

(28) The construction block 100 may be assembled in a vertical wall or other structure (as an “A-block”) in a manner similar to block 10. Alternatively, as demonstrated in FIGS. 14-16, the knock-out end wall 113 may be broken away from the construction block 100 using a hand tool 150 or other device impacting the block 100 along or adjacent one or more score lines 141-143. The multiple score lines 141-143 facilitate clean and controlled separation of the end wall 113, thereby transforming the exemplary “A-block” to an “H-block” having only a single narrow cross-web 114. The narrow cross-web 114 may offer reduced heat loss through the block 100 via thermal bridging, and may limit other negative effects caused by thermal bridges. A partial vertical wall “W” constructed using an assembly of the present blocks 100 with respective knock-out end walls 113 broken away is illustrated in FIG. 19.

(29) For the purposes of describing and defining the present invention it is noted that the use of relative terms, such as “substantially”, “generally”, “approximately”, and the like, are utilized herein to represent an inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

(30) Exemplary embodiments of the present invention are described above. No element, act, or instruction used in this description should be construed as important, necessary, critical, or essential to the invention unless explicitly described as such. Although only a few of the exemplary embodiments have been described in detail herein, those skilled in the art will readily appreciate that many modifications are possible in these exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the appended claims.

(31) In the claims, any means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. Unless the exact language “means for” (performing a particular function or step) is recited in the claims, a construction under §112, 6th paragraph is not intended. Additionally, it is not intended that the scope of patent protection afforded the present invention be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.