Abstract
A mortarless block system for forming walls from blocks which are stackable in sequential rows upon each other. Upper rows of blocks positioned upon lower rows are securable by positioning of support rods through aligned passages thereof. The passages extend between upper and lower notches in each respective block. The support rods are engaged to connectors which are sized to fit completely within the notches to thereby leave the upper and lower surfaces of each lower row flush to stacking overhead rows thereon.
Claims
1. A mortarless block system comprising: a block, said block having a top surface and a bottom surface opposite said top surface; said block having a first side communicating between said top surface and said bottom surface and having a second side opposite said first side; said block having a first endwall opposite a second endwall; a first plurality of upper notches forming recessed areas in said top surface of said block; a second plurality of lower notches each forming recessed areas into said bottom surface; each of said upper notches being aligned with a respective one of said lower notches to form aligned pairs of notches; passages running through said block between each of said aligned pairs of notches; and a plurality of said blocks positionable in stacked rows of said blocks in adjacent positions to each other to form a wall.
2. The mortarless block system of claim 1, additionally comprising: said block having a hollow interior cavity by an area surrounded by said top surface, said bottom surface, said first side, said second side, said first endwall and said second endwall; said block having a fill opening communicating with said interior cavity for deposit of fill material therein.
3. The mortarless block system of claim 1, additionally comprising: a connector bracket for holding an upper row of said blocks in said stacked row positioned atop a lower row of said blocks in said stacked row, where upper said passages running through each said block in said upper row are aligned with lower said passages in each said block in said lower row; said connector bracket having a support rod running through both said upper passages and said lower passages; a first end of said support rod having a first connector engaged thereto, said first connector dimensioned to fit within a said upper notch on a said block in said upper row; and a second end of said support rod engaged with a second, said second connector dimensioned to fit within a said lower notch of a block in said lower row.
4. The mortarless block system of claim 2, additionally comprising: a connector bracket for holding an upper row of said blocks in said stacked row positioned atop a lower row of said blocks in said stacked row, where upper said passages running through each said block in said upper row, are aligned with lower said passages in each said block in said lower row; said connector bracket having a support rod running through both said upper passages and said lower passages; a first end of said support rod having a first connector engaged thereto, said first connector dimensioned to fit within a said upper notch on a said block in said upper row; and a second end of said support rod engaged with a second said connector dimensioned to fit within a said lower notch of a block in said lower row.
5. The mortarless block system of claim 3, additionally comprising: said support rod having a first section extending from said first end thereof to a first distal end; said support rod having a second section extending from said second end thereof, to a second distal end; and said first section of said support rod being engageable to said second section of said support rod by a connector at said first distal end which is engageable with a mating connector positioned at said second distal end.
6. The mortarless block system of claim 1, additionally comprising: a respective secondary recess formed into said first side of said block adjacent each of said first plurality of upper notches and each of said second plurality of lower notches.
7. The mortarless block system of claim 2, additionally comprising: a respective secondary recess formed into said first side of said block adjacent each of said first plurality of upper notches and each of said second plurality of lower notches.
8. The mortarless block system of claim 3, additionally comprising: a respective secondary recess formed into said first side of said block adjacent each of said first plurality of upper notches and each of said second plurality of lower notches.
9. The mortarless block system of claim 4, additionally comprising: a respective secondary recess formed into said first side of said block adjacent each of said first plurality of upper notches and each of said second plurality of lower notches.
10. The mortarless block system of claim 5, additionally comprising: a respective secondary recess formed into said first side of said block adjacent each of said first plurality of upper notches and each of said second plurality of lower notches.
11. The mortarless block system of claim 4, additionally comprising: said first end of said support rod being in a rotational engagement with said first connector.
12. The mortarless block system of claim 4, additionally comprising: said first end of said support rod being in a rotational engagement with said first connector.
13. The mortarless block system of claim 3, additionally comprising: corner brackets for securing corner intersections of said blocks forming said wall; said corner brackets having tabs projecting therefrom having tab openings therein; and said tab openings dimensioned to fit entirely within said upper notches of abutting said blocks at a said corner intersection.
Description
BRIEF DESCRIPTION OF DRAWING FIGURES
[0022] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate some, but not the only or exclusive examples of embodiments and/or features of the disclosed mortarless block configuration and construction method herein. It is intended that the embodiments and figures disclosed herein are to be considered illustrative of the invention herein, rather than limiting in any fashion.
In the drawings:
[0023] FIG. 1 depicts a perspective view of a block formed pursuant to the system and method herein and showing multiple connection areas for adjacent underlying and overlain blocks.
[0024] FIG. 2 depicts a frontal view of the block of FIG. 1 and shows notches formed for both structural attachments as well as recesses for stiffening the sidewall of the formed block.
[0025] FIG. 3 depicts a top view of the block of FIGS. 1-2, where the bottom view would be a mirror image and shows a plurality of passages communicating through the block, which are positioned within respective notches formed on the top side surface and bottom side surface of the block.
[0026] FIG. 4 shows a block of the system herein, which is formed in a unitary structure within the block and on the surfaces of the block.
[0027] FIG. 5 depicts a mode of the block herein, wherein the block is formed in a body having a sidewall having an exterior surface and defining an interior cavity which is filled with corrugated or other fill material, thereby significantly reducing weight and shipping costs.
[0028] FIG. 6 shows a mode of the block herein, similar to that of FIG. 5, wherein the body of the block is formed a sidewall defining an interior cavity, which may be filled on site through a fill aperture.
[0029] FIG. 7 shows the block herein of FIGS. 1-6, and depicts the notches formed into the top and recesses in the sidewall of the exterior of the block, which are configured for positioning of support structures for roofs and the like, as well as connectors which are configured to engage with support rods shown in FIGS. 8-10 to allow for compression.
[0030] FIG. 8 depicts an overhead view of the blocks herein formed to two adjacent parallel walls and having support members engaged therebetween across a formed gap between the two walls.
[0031] FIG. 8A depicts a perspective view of the blocks herein formed to two adjacent parallel walls and having support members engaged therebetween across a formed gap between the two walls.
[0032] FIGS. 9-11 depict various configurations of support rods which are employed through the aligned passages in stacked blocks to hold them in engagement.
[0033] FIG. 12 shows an example of a plurality of the blocks herein, in a stacked engagement with support rods operatively engaged therethrough.
[0034] FIG. 13 is a perspective view of the formed wall of FIG. 12 showing the stacking of the blocks which are engaged with support rods connected between adjacent stacked blocks.
[0035] FIG. 14 shows the positioning of an overhead block upon an underlying block to form a stacked configuration and also shows L-shaped connectors engaged with the support rods.
[0036] FIG. 15 depicts an example of a support rod which can be positioned as in FIG. 14 to have a tapered portion thereof projecting above the top surface of a lower positioned block.
[0037] FIG. 16 depicts a connector bracket herein where the support rod is engaged to the connector which is L-shaped.
[0038] FIG. 17 shows a connector bracket having an L-shape in which the support rod is rotationally engaged in a permanent engagement whereby the support rod can be rotated to achieve a connection to a nut, bracket or other support rod.
[0039] FIGS. 18-19 depict another configuration for the connector bracket which has an L-shaped connector engaged to the support rod and also has a projecting base.
[0040] FIG. 20 shows a row of blocks in a transparent rendering showing different connector brackets engaged on opposite sides of the blocks.
[0041] FIGS. 21-23 depict side and inner and outer corner brackets of the system herein which are engageable with projecting taps adapted for recessed positioning within the notches.
[0042] FIGS. 24-25 show examples of a wall portion having the brackets of FIGS. 21-23.
[0043] FIG. 26 shows an example of a wall formed by blocks at an angle to each other and held in that position by an angled support rod shown in FIG. 27.
[0044] FIG. 27 shows a curved mode of the support rod 40 engaged with connectors 30, which can be employed to form the angled wall of FIG. 26.
DETAILED DESCRIPTION OF THE INVENTION
[0045] In this description, the directional prepositions of up, upwardly, down, downwardly, front, back, top, upper, bottom, lower, left, right, first, second, and other such terms refer to the device as it is oriented and as it appears in the drawings, and all such terms are used for convenience only and such are not intended to be limiting or to imply that the device has to be used or positioned in any particular orientation.
[0046] Now referring to drawings in FIGS. 1-27, wherein similar components are identified by like reference numerals, there is seen in FIG. 1, a perspective view of a block 10 formed pursuant to the system and method herein. As shown, the block 10 is formed of a body having an exterior surface which includes a plurality of upper notches 12 which are formed into a top surface 14 and a plurality of aligned lower notches 13 formed into the bottom surface 16 of the body of the block 10. These upper notches 12 and lower notches 13 may intersect with vertical secondary notches 18 which are formed into a first side 20 of the body of the block 10.
[0047] Also shown are a plurality of recesses 22 which depend into the first side 20 of the body of the block 10. These recesses 22 have been shown, in experimentation, to reduce the weight of the block 10 when formed in a unitary structure with the interior formed of the same material as the exterior of the body of the block 10 when the body of the block 10 is formed with an exterior surface which surrounds an interior cavity 24 as in FIGS. 4-6. The recesses 22 have been found in experimentation to provide for a stronger sidewall of the body of the block 10 where the exterior surface surrounds and defines the interior cavity 24.
[0048] By exterior surface is meant top surface 14 and the bottom surface 16, which connect between the first side 20 and an opposite second side 21 of a block 10 and between a first endwall 25 and between a second endwall 27, such as in FIG. 1. The exterior surface can be formed to hold the shape of the block 10 in modes which are formed hollow for inexpensive shipping. In this hollow mode, this exterior surface of the block 10 device herein, can be formed by molding to form a skin or exterior surface which can later be filled with cementacius or other material. Such may be by injection molding or polymeric or cementacius or other materials which can later be filled. In solid modes of the block 10, it would be formed as conventional solid core cementitious blocks such as cinder blocks.
[0049] Shown in FIG. 2 is a view of the first side 20 of the block 10 herein positioned opposite a second side 21. As shown, the secondary notches 18 are positioned to intersect the upper notches 12 forming recesses into the top surface 14 and aligned lower notches 13 formed into recesses in the bottom surface 16. This intersection is substantially perpendicular. A plurality of the recesses 22 are shown formed into the first side 20 of the exterior surface of the body of the block 10 and could be formed into the second surface 21. Although, currently, a smooth flat second surface 21 is preferred.
[0050] The upper notches 12 and lower notches 13 and the intersecting secondary notches 18 if included, are configured to allow for positioning of structural support members 28 and any required nuts or fasteners therein, such as in FIGS. 7 and 8, whereby the support members 28 are positioned below the top surface 14 so as to allow for level positioning of additional rows of blocks 10 thereon.
[0051] In FIG. 3 is shown a top view of the body of the block 10 of FIGS. 1-2 and showing the plurality of upper notches 12 formed into the top surface 14, each defining a recessed area. As noted, preferably aligned lower notches 13 are preferably also formed into the bottom surface 16 of the block 10, each in aligned positions with those in the top surface 14.
[0052] Also shown are a plurality of passages 26 which communicate through the body of the block 10 from the top surface 14 to the bottom surface 16. These passages 26, as noted below, are configured for positioning of support members 28 therein. The support members 28 will extend through aligned passages 26 of each row of stacked blocks 10 and may have connectors 30 (FIG. 7) engaged and tightened on both ends of the support members 28, to impart a compressive force to the stacked blocks 10 in formed wall structures such as shown in FIGS. 8, and 12-13. The connectors 30 are preferably sized for positioning entirely within an upper notch 12 or lower notch 13 such that it does not project above the adjacent top surface 14 or bottom surface 16 of the block 10.
[0053] In FIG. 4 is depicted a unitary structure form of the block 10 herein. As shown, the interior area of the block as well as the exterior surface, are formed of a single material, such as a cementitious material or a polymeric material.
[0054] Depicted in FIG. 5 is a mode of the block 10 herein, wherein the block 10 has a body where the top surface 14 bottom surface 16, first side 20 and second side 21, are formed by a sidewall 32. This sidewall 32 defines an interior cavity 34. This interior cavity 34 may be filled with a different material from that forming the body defined by the sidewall 32. In this mode of the block 10, the weight is significantly reduced by the formation of the hollow interior cavity 34 making it easier to carry and less expensive to ship.
[0055] As shown in FIG. 5, the interior cavity 34 is filled with a corrugated material 36 which provides strength to the formed block 10. Where the fill material within the interior cavity 34 is not a liquid or powder, it may be positioned within the interior cavity 34 during molding of the body of the block 10, such as by co-molding.
[0056] In FIG. 6 is depicted a mode of the block 10 herein, similar to that of FIG. 5, but where the body of the block 10 as defined by the sidewall 32 defines an interior cavity 34, which may be filled on the construction site through a fill aperture 38 which is sealable and communicates with the interior cavity 34. In this mode, the fill material might be any liquid 35, such as a gel, or flowing material which solidifies when mixed with water or another liquid which may be poured though the fill aperture 38. This mode of the block 10 is especially lightweight and can be easily and cheaply shipped. In this mode the passages 26 are formed by the sidewall 32 which surrounds them, and thus they are sealed from the material which is placed within the interior cavity 34. The body of the block 10 in this mode may be formed by molding of the material forming the sidewall 32, such as a polymeric material which is UV inhibited and has a long lifespan such as polypropylene, polyethylene, or another polymeric material as would occur to those skilled in the art.
[0057] Shown in FIG. 7 is a block 10 herein, such as those of FIGS. 1-6. Connectors 30 of the system herein are shown, which are configured to engage with or have support rods 40 engaged thereto as in FIGS. 16-19 for example. Each support rod 40 is sized for sliding engagement within and through the passages 26 of the blocks 10 such as when positioned to form structures as in FIGS. 12-13. As noted, the support rods 40 are preferably formed to taper from a larger cross section adjacent the connectors 30 to a narrower cross section at distal ends thereof. This taper allows for easier positioning of the blocks 10 onto the support rods 40. The hollow passages 26 communicating between the top surface 14 and bottom surface 16 of the blocks 10 preferably have a shape and cross section which matches the shape and cross section of the support member 28 inserted therein to achieve contact therebetween across the length of the passages 26.
[0058] These connectors 30, as shown in FIGS. 7 and 15-19, are sized for a recessed positioning with the upper notches 12 and lower notches 13 which surround the openings into passages 26 through which the support rods 40 communicate. A tightening of the engagement between the connectors 30 and the support rods 40 at opposing ends thereof, will impart a compressive force to the stacked rows of blocks 10 to enhance stability. This can be achieved by fasteners such as nuts 31 which engage with a threaded end 41 of a support rod 40 projecting through a planar connector 30 or threaded aperture therein.
[0059] Alternatively, where the connectors 30 are L-shaped, as in FIGS. 16-19, a rotating engagement of the support rods 40 with the connector 30 as in FIG. 17 will provide the ability to impart compression to the wall formed. As shown in FIG. 17, for example, the support rod 40 is in a rotating connection 43 with the connector 30 and can be rotated therein, to tighten the threaded end 41 into and with the threaded recess 45 of the distal end of another support rod 40. The L-shaped connectors 30 of FIGS. 16-17 can have either a threaded end 41 or threaded recess 45 (FIG. 15) therein.
[0060] Shown in FIG. 7 is an example of the system herein, wherein two walls are formed by blocks 10 allowing for positioning of soil or insulation therebetween. In this mode a support member 28, which like the connectors 30, is dimensioned to fit into the upper notches 12 and lower notches 13 and be recessed below the top surface 14 or bottom surface 16 to make those surfaces level. Such support members 28 may be employed to hold a roof elevated, for example, or when two rows of blocks 10 are engaged by such support members 28 as in FIG. 8 or 8A, or in other construction as would occur to those skilled in the art.
[0061] Shown in FIGS. 8 and 8A are overhead views of this mode of the block system herein, wherein the blocks 10 are stacked in layers and rows to form two adjacent parallel walls. This configuration is especially well adapted to enhance stability of a structure and to allow for positioning of insulation or other material in between the two walls. As shown, support members 28 are dimensioned for recessed engagements into respective notches 12 or 13 and are engaged between the two walls formed of blocks 10. Support rods 40 are communicated through openings in each connector 28 to hold both the support rods 40 and to compress the blocks 10 and to hold the support members 28 in place.
[0062] In FIGS. 9-11 are shown various configurations of support rods 40 which may be employed with the system herein. The support rods 40 may be cooperatively threaded on opposing ends which are adapted to engage with either threaded connectors 30, nuts 31, or threaded recesses 45 of additional support rods 40 so as to elongated them. The depicted configurations of the support rods 40 are not exclusive and such may be configured as would occur to those skilled in the art. Also, while the removable connection between support rods 40 is noted as threaded, it can also be other removable engagements between a distal end of one support rod 40 and that of another support rod 40, such as a bayonet mount, or other engagement as would occur to those skilled in the art.
[0063] In FIGS. 12-13 are depicted examples of the blocks 10 herein stacked adjacently in sequential rows, to form wall-like structures. As shown for convenience in a transparent rendering, the blocks 10 are positioned with their respective passages 26 aligned, and with respective support rods 40 operatively engaged within the passages 26. Appropriate connectors 30 engage with the support rods 40 to hold the blocks 10 stacked and in position. For example, the support rods 40, are shown in engagements in FIGS. 15-19 where the connector 30 is L-shaped and dimensioned for a recessed positioning within an upper notch 12 on a top surface 14 or lower notch 13 on a bottom surface 16, and an adjacent intersecting secondary notch 18 forming a second recess in the first side 20 of the block 10. The connectors 30 fit entirely in the respective upper notch 12 or lower notch 13 to maintain flush or level surfaces for stacking the blocks 10 on each other.
[0064] In FIG. 14 is shown an example of the positioning of an overhead block 10 upon an underlying block 10 to form a stacked configuration. Also shown are the L-shaped connectors 30 engaged with the support rods 40 projecting into the bottom of the formed wall, and an elongated support rod 40 as in FIG. 15, wherein a tapered portion thereof projects above the top surface 14 of the lower positioned block 10 for positioning of the passages 26 of the upper positioned block 10 thereon.
[0065] Shown in FIG. 15, is an example of an elongated version of the support rod 40 which can be positioned as in FIG. 14 to locate a secondary tapered portion thereof, projecting above the top surface 14 of a lower positioned block 10. As noted another block 10 is easily positioned on the lower block 10 by sliding the passages 26 over the projecting secondary tapered portions of the support rods 40.
[0066] Shown in FIGS. 16 and 17, is a connector bracket herein where the support rod 40 is engaged to the connector 30 which is L-shaped. The support rod in FIG. 17 is rotatable in the engagement with the connector 30.
[0067] In FIGS. 18-19 are shown modes of the connector bracket wherein the connector 30 is L-shaped, and on an opposite side of the connector 30 from that of the support rod 40, is positioned a mount 46 which can be buried in the ground or in a cement layer, to hold the connector bracket in place.
[0068] In FIG. 20 is shown various connector brackets in operative connections through the bottom and top surfaces of a wall formed of adjacently stacked blocks 10. As shown, the connector brackets of FIGS. 16-17 are used for a base, and a connector bracket as in FIGS. 16 and 17 are engaged on the top of the wall. While shown as a single block row in a layer, the connector brackets on the top would be used in the same fashion where a second or third row of blocks 10 are stacked. Because all of the connectors 30 are sized to fit completely in a respective upper notch 12 or lower notch 13 when engaged with a support rod 40, the top surface of each row remains flush, for the level stacking of the next row thereon to form the wall.
[0069] FIGS. 21-23 depict side brackets 48 inner and outer corner brackets 50 of the system herein which are engageable to the blocks 10 with projecting tabs 54 adapted for recessed positioning within the upper notches 12. Examples of positioning of the corner brackets 50 and side brackets 48 are shown in FIGS. 24 and 25. Tab openings 54 allow for passage of the support rods 40 therethrough.
[0070] It should be noted that any of the different depicted and described configurations and components of the block and structures formed thereby, can be employed with any other configuration or component shown and described as part of the block device and building system herein. Additionally, while the present invention has been described herein with reference to particular embodiments thereof and/or steps in the method of production or use, a latitude of modifications, various changes and substitutions are intended in the foregoing disclosure, and it will be appreciated that in some instance some features, or configurations, of the invention could be employed without a corresponding use of other features without departing from the scope of the invention as set forth in the following claims. All such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this invention as broadly defined in the appended claims.
