Abstract:
A wall comprising superposed rows of aligned conventional building blocks being approximately parallel front and back faces connected by a plurality of transverse webs defining chambers there between in which the tops and bottoms of the blocks are formed with V-shaped grooves to mate with similarly shaped V-shaped grooves in the adjacent wall or a block placed thereon. Tubing is placed within the adjacent V-shaped grooves to space the blocks from each other and maintain the adjacent rows in proper alignment. Lateral temperature rods may be placed inside the tubes.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates to a building block assembly and, particularly, to an arrangement which incorporates a system for aligning the blocks in vertical and horizontal relationships.  
       BACKGROUND OF THE INVENTION  
       [0002]     The conventional concrete block has been recognized as the least expensive construction material and is a very versatile material since it is both, fire-safe, sound-deadening, and absorbing. It also can be made decorative and is readily available all around the world. Furthermore, it is essentially maintenance free and indestructible. In addition, it is obviously termite-safe and almost tenant-safe. The production of building blocks of this type is highly mechanized and economically productive. However, it does depend for its accurate installation on highly skilled labor. Many attempts have been made to mechanize the installation by using cheap, unskilled labor, but it is not generally satisfactory due to the potential of inaccurate positioning of the interfitting blocks and resulting need for parching, which is very costly. An arrangement that has been employed is my U.S. Pat. No. 4,514,949 which has been generally satisfactory, but it has been found that the point contact occurring with the utilization of spherical balls is not as effective as desired, including the need for light parching.  
         [0003]     The general problem that exists, of course is that the existing block producing machines cannot make the blocks accurate to more than 0.050 of an inch in height, and because of this, the accepted tolerance is ± 1/16 of an inch, which in extreme instances can be up to ⅛ of an inch. Accordingly, some means must be provided to accommodate this variation in height to insure proper alignment. Accordingly, it is the purpose of this invention to provide a building block assembly which by the utilization or unskilled workers a wall or similar construction can be constructed with accurately positioned rows of building blocks.  
       SUMMARY OF THE INVENTION  
       [0004]     In accordance with the present invention, there is provided a building block arrangement which is constructed with V-shaped grooves along the longitudinal walls thereof in which are fitted plastic tubes or plastic reinforced tubes that insure proper alignment of horizontally or vertically disposed rows of building blocks. While this may appear to be a relatively simple construction, it is of an order of magnitude that with the provision of such grooves, the tubes are able to insure proper alignment and thus level rows of building blocks, thus providing the temperature reinforcing rods within the tubes.  
         [0005]     In addition, the slot/guide arrangement of the present invention facilitates the process of mounting blocks typically used in residential and commercial construction. Furthermore, the present invention provides a clean process, where no cement between blocks is used, thus increasing not only the speed of the installation process but the number of blocks installed per time frame and at the same providing the opportunity of using untrained labor for the installation.  
         [0006]     Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of the invention and embodiments thereof, from the claims and from the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]     Further features and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying figures showing illustrative embodiments of the invention, in which:  
         [0008]      FIG. 1  shows an exploded perspective view of a three-chamber building block assembly according to an embodiment of the invention;  
         [0009]      FIG. 2  shows a front elevation view of two aligned superposed building blocks according to an embodiment of the invention;  
         [0010]      FIG. 3  shows a front elevation view of three building blocks in staggered relation to each other according to an embodiment of the invention;  
         [0011]      FIG. 4  shows a partial perspective view of two reinforced masonry wall sections according to an embodiment of the invention;  
         [0012]      FIG. 5  shows a cross section view of a wall footing from a ground floor slab according to an embodiment of the invention;  
         [0013]      FIG. 5A  shows a side view of a wall footing from a ground floor slab according to another embodiment of the invention;  
         [0014]      FIG. 5B  shows a perspective view of a wall footing from a ground floor slab according to another embodiment of the invention;  
         [0015]      FIG. 5C  shows a side view of a wall footing from a ground floor slab according to another embodiment of the invention;  
         [0016]      FIG. 5D  shows a perspective view of a wall footing from a ground floor slab according to another embodiment of the invention  
         [0017]      FIG. 6  shows a perspective view of an interconnection between a door frame and a building block according to an embodiment of the invention;  
         [0018]      FIG. 7  shows a partial perspective view of a roof block interconnection arrangement according to an embodiment of the invention;  
         [0019]      FIG. 8  shows a perspective view of a block modifying machine according to an embodiment of the invention; and  
         [0020]      FIG. 8A  shows a cross section view of a block modifying machine according to an embodiment of the invention. 
     
    
       [0021]     Throughout the figures, the same reference numbers and characters, unless otherwise stated, are used to denote like elements, components, portions or features of the illustrated embodiments. The subject invention will be described in detail in conjunction with the accompanying figures, in view of the illustrative embodiments. It is clear that changes and modifications to the described embodiments can be made without departing from the scope and spirit of the present invention as defined by the appended claims.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0022]     Referring first to  FIG. 1 , there is illustrated a building block  20  having grooves  22 ,  24  formed in longitudinally extending walls  23 ,  25 , respectively. Disposed in the grooves for alignment of adjacent blocks are provided either a plain plastic tubing  26  shown in exploded view or a plastic tubing  26  with a reinforcing wire  28  disposed therein. The tubing used has an outside diameter of ⅜″. Both of these arrangements are shown and either of them can be employed if desired. Chambers  30  are defined by the webs  31  and sidewalls  23 ,  25 .  
         [0023]     Referring to  FIG. 2 , the two building blocks  20  are shown in vertical alignment with plastic tubing  26  disposed relative thereto. A longitudinal end view of this arrangement can be seen from  FIG. 5 . It is to be noted that the diameter of the tubing and the depth of the V-shaped grooves are such that a slight spacing  33  is provided between vertically disposed blocks  20  to insure proper alignment. The spacing between the blocks varies between 0 to ⅛″ according to block height error, although may be substantially reduced to a spacing between 0.010″ and 0.020″ by grinding the block bottoms while grinding the V-cuts.  
         [0024]     Referring now to  FIG. 3 , the arrangement is disposed with the adjacent rows of building blocks located in a staggered relationship. It will be noted that the upper building block  20  overlaps the junction of the lower building blocks  20 .  
         [0025]     In  FIG. 4 , there are shown in partial perspective two masonry walls constructed of building blocks  20  that include reinforcing steel rods  32  that are disposed in the longitudinal and transverse direction. These rods are utilized to reinforce the structures and extend through the chambers  30  of the building block, which will serve to conduct all utilities wiring, ducts, etc. If desired, reinforced concrete  34  is poured into the chambers. There are also provided vertically extending reinforced concrete columns  36 .  
         [0026]     At the bottom of  FIG. 4 , there is also shown in perspective the connection between the concrete slab  38  and the building blocks  20 . To provide for proper leveling of the building blocks, there are located on the slab  38  leveling channels  40 . These channels are secured to the blocks by leveling bar  42  and a rod as shown in section  45 . In order to properly level the building blocks relative to the concrete slab, there is a leveling device comprising of bracket  44  through which is disposed a leveling screw  46 . The concrete blocks are disposed on the horizontally extending portion of bracket  44  as shown in section  45  and their positions are adjusted relative to the floor slab by adjusting the leveling screws  46 . Thus, it can be seen that by adjusting the leveling screws, the level position of the blocks located in the leveling bracket are set. As shown in  FIG. 5 , and as briefly explained earlier in this application, the adjacent rows are aligned relative to each other by the use of the plastic tubing  26  disposed in groves  22 ,  24  of each block.  
         [0027]      FIG. 5A  shows an alternate embodiment of a block leveling means. A vertical retaining means  65  is properly secured to the concrete slab by any known conventional securing means. A second retaining means  64  is securely attached to the building blocks  20  to cooperate with said retaining means  65  when the blocks  20  are vertically positioned against the floor slab  38 . A fixing means  60  is properly secured to building blocks  20  to selectively allow leveling of said blocks  20 . Lower stopper  61  serves to hold the bottom of block  20  in a static position relative to side stopper  68 . A leveling means  66  is secured to the concrete slab  38  and the upper stopper  63  to selectively allow leveling of the block relative to the concrete slab  38 . Leveling means  66  comprises a lower part  70  including a thread end and an upper part  71  including a thread end, which cooperate together in conjunction with adjuster  67  to selectively level the block  20  by rotating said adjuster  67  in a clockwise/counter-clockwise manner. Upper part  71  and upper stopper  63  are structurally connected to a hinged clamp  72  to fixedly secure an inner wall of block  20  in relation to said fixing means  60  as shown in  FIG. 5A . Empty space  62  is filled with concrete to allow proper fixation to the concrete slab.  
         [0028]      FIG. 5B  is another view of an alternate embodiment of said block leveling means. A plastic tubing  26  in a mating relationship with a v-shaped groove serving as a lower stopper to retain said block fixed in relation to the concrete slab  38 . hinged clamp  72   b  fixedly secures an inner wall of block  20  in relation to fixing means  60   b.    
         [0029]      FIGS. 5C and 5D  show another embodiment of the present invention. A second hinged clamp including a clamp element  80   a  and a hinge element  81   a  is provided to further retain said block fixed in relation to a second fixing means  82   a.  Clamp element  80   a  is inserted inside an inner wall of block  20  in such a way as to push block  20  against second fixing means  82   a  when hinge element  81   a  is actuated in an outwardly manner. Lower stoppers  61   a  and  61   b  retain block  20  horizontally fixed in relation to the floor or concrete slab  38 .  FIG. 5D  shows a plurality of blocks selectively positioned adjacent to each other in an embodiment of the invention to form a wall. Blocks  20  are filled with cement or any suitable filler which is eventually dried. Then, both clamps are removed and another round of blocks is positioned above the already dried blocks using the inventive method. The combination of said upper second hinged clamp and said second fixing means  82   a  is an alternative to the lower fixing means  60  described in  FIG. 5A .  
         [0030]     In  FIG. 5 , the height tolerances are more clearly shown with respect to the two superposed blocks illustrated therein. From the centerline of the tubes, regardless of the block heights that may vary from 7⅝ inches to 7¾ inches, the distance from center line to center line of the tubing  26  is 7.875 inches (20 cm)± from about 0.002″ to about 0.004″ in tolerance. It is possible to obtain such close tolerances because of the precise machining of the grooves during drilling. By providing such small tolerance values it is possible to avoid applying cement to the exterior faces of said blocks  20 .  
         [0031]     When it is desired to mount a door frame relative to a block having the novel construction of the V-shaped grooves in the upper walls thereof, there is provided a door frame  48  in which is located a steel plate connector  50 . This connector is positioned in a slot  52  formed in the wall of the building block to retain the door frame in place relative to the building block as shown in  FIG. 6 .  
         [0032]      FIG. 7  shows the concept of the present invention implemented for building a roof. Channels  90  are provided between blocks  20  to hold them together.  
         [0033]     Protrusions  91  are provided to accept inventive rods  92  that will fit into the V-shaped grooves of blocks  20 , while reinforcing bars and concrete are used to fill the space within blocks  20 .  
         [0034]      FIGS. 8 and 8 A show a novel machine used to modify building blocks according to one embodiment of the invention. A movable means  100  such a conveyor means is used to properly move the blocks inside, within, and outside of said machine. The movable means is also adapted to ensure that the blocks are substantially positioned in a fixed position without any vertical and/or horizontal movements during the modifying process. To achieve said above mentioned goal, a three-chains arrangement is selectively positioned in relation to said conveyor means to ensure optimal movement and to avoid any loose movement of said blocks while entering the machine. Moreover, a pre-cutting stage could be provided to selectively adjust the height of said blocks to a uniform height before entering a cutting stage. The blocks  20  enter the machine through an opening  105  that substantially fits the outer surface of said blocks  20 . A selected clearance between said outer surface and said opening could also be provided. Once the blocks are inside the machine, grinding wheels are used to produce the V-shaped grooves at the bottom and upper part of said blocks. Preferably, diamond dust grinding wheels are used. The grinding wheels are powered by motors  101 . In the preferred embodiment the motors are 3-phase, 5 hp motors, which are selectively and individually controlled. The motors could also be controlled together by a single controlling means.  
         [0035]     It can be seen from the above that a novel construction is provided whereby the building blocks  20  can be maintained in level position relative to the ground slab. Also, they can be uniformly placed in a level, condition throughout the length of the walls, as shown in  FIG. 4 , by the utilization of plastic tubing that is located in the V-shaped grooves formed in the upper walls of the building blocks. The V-shaped grooves are actually formed in both ends of the main walls of the building block and therefore they can be readily installed in position during construction. Blocks  20  can be made of any suitable material regardless of its compression characteristics. The resistance of the wall is controlled by the blocks column and the joint of the top and bottom surfaces. Moreover, the interior part of the wall defined by chambers  30  can be fill by any suitable filler. The present invention avoids the formation of cracks by voids in the the columns.  
         [0036]     It is intended to cover by the appended claims all such modifications which fall within true spirit and scope of the invention.