BUILDING BLOCK

Abstract: A masonry block (10, 30, 350, 410) having a rib (11, 31, 351, 411) on one load bearing surface (13, 32, 354, 413) which is received by a channel (12, 33, 352, 412) on the opposite load bearing surface (18, 34, 355, 418) of a like block (10, 30, 350, 410). A slot (17, 40, 356, 417) and/or aperture (15, 35, 353) extends between the load bearing surfaces (12, 33, 352, 412; 18, 34, 355, 418) and is intended to receive mortar or cement. The load bearing surfaces (12, 33, 352, 412; 18, 34, 355, 418) of adjacent courses of blocks (10, 30, 350, 410) do not receive mortar and a substantially weatherproof seal is provided by the ribs (11, 31, 351, 411) and channels (12, 33, 352, 412). Corner blocks (130, 230, 430, 450) for corners and T intersections are also disclosed.

Description: "BUILDING BLOCK" . TECHNICAL FIELD The present invention relates to building blocks and in particular, to masonry building blocks, a method of laying su blocks, and buildings constructed from such blocks. Masonry blocks are well known, and have application in the building of various types of walls and structures particularly since there is an economic advantage in using these blocks rather than conventional "house bricks" because kiln baking is not required. The prior art masonry building blocks do, however, have disadvantage in common with conventional "house bricks". Thi disadvantage stems from the need for expertise in the art of brick laying before a structurarly sound and asthetically pleasing result can be obtained using the building blocks. I particular, the difficulty arises in ensuring that strong, ne and uniform joints are obtained between each block, ensuring that the correct alignment of the blocks is maintained, and ensuring a weatherproof seal is formed between the blocks. It is an object of the present invention to provide bot a masonry building block and a method of laying same which will overcome, or substantially ameliorate, the above- mentioned disadvantages. DISCLOSURE OF INVENTION According to one aspect of the present invention there i disclosed a masonry block having a rib extending along one (upper) surface thereof, a channel extending along the opposit (lower) surface thereof, and slot means communicating between said channel and rib, said rib of one of said blocks being insertable in the channel of a like block. Preferably, the rib and channel extend longitudinally and the rib is terminated at one end of the block by an open slot means which extends between the upper and lower surfaces of the block. In another preferred form, an elongate protrusion is formed on the end of the block opposite to the open slot means the protrusion being adapted to fit into the open slot means o a like block. OMPI WIPO & : ^_?_.Y_ιτϊϊOn^ BRIEF DESCRIPTION OF DRAWINGS Some embodiments of the present invention will now be described with reference to the drawings in which: Fig. 1 is a perspective view of a masonry building block of a first embodiment; Fig. 2 is a perspective view of the building block shown in Fig. 1 when viewed in the opposite direction? Fig. 3 is a inverted plan view of a building block of th first embodiment and; Fig. 4 is a perspective -view of a plurality of the ' building blocks of Fig. 1 showing how the building blocks are fitted together to form a wall;- Fig. 5 is a side view of a masonry building block of a second embodiment; Fig. 6 is a plan view of the building block of Fig. 5; Fig. 7 is an inverted plan view of the building block of Fig. 5; Fig. 8 is a view from one end of the building block of Fig. 5; Fig. 9 is a view from the other end of the building bloc of Fig. 5; Fig. 10 is a side view of a corner block for use with th building block of Fig. 5; Fig. 11 is a plan view of the building block of Fig. 10; Fig. 12 is an inverted plan view of the building block o Fig. 10; Fig. 13 is a view from one end of the building block of Fig. 10; Fig. 14 is a view from the other end of the building block of Fig. 10; Fig. 15 is a side view of a T block for use with the building block of Fig. 5; Fig. 16 is a plan view of the building block of Fig. 15; Fig. 17.is an inverted plan view of the building block o Fig. 15; Fig. 18 is a view from one end of the building block of Fig. 15; Fig. 19 is a view from the other end of the building O PI block of Fig . 15 ; Fig. 20 is a plan view of a masonry building block of a third embodiment; Fig. 21 is a side view of the building block of Fig. 20; Fig. 22 is an end view of the building block of Fig. 20; Fig. 23 is an inverted plan view of the building block o Fig. 20; Fig. 24 is a perspective view of a masonry building bloc of a fourth embodiment; ' Fig. 25 is a perspective view of the building block show in Fig. 24 when viewed from the opposite direction; Fig. 26 is a plan view of the building block shown in Fig. 24; Fig. 27 is a plan view of a corner block for use with th building block of Fig. 24; Fig. 28 is a side view of the building block of Fig. 27; Fig. 29 is an inverted plan view of the building block o Fig. 27; Fig. 30 is a plan view of a T block for use with the building block of Fig. 24; Fig. 31 is a side view of the building block of Fig. 30; and Fig. 32 is an inverted plan view of the building block o Fig. 30. MODES FOR CARRYING OUT THE INVENTION As seen in Figs. 1, 2 and 3, the masonry building block 10 of the first preferred embodiment is a generally rectangula prism with a rib 11 extending along the upper surface 13 and a channel 12 extending along the lower face 18. A cylindrical aperture 15 extends from the upper surface 13 to the channel 1 and provides an inter-connection there between. A trough 17 divides the end surface 19 in two. Thus, th rib 11 is terminated by the trough 17 and does not extend to the end surface 19. Also as seen in Figs. 1, 2 and 3, two half round grooves 14 and 16 are formed in the face 20 along the edges joining it with the lower surface 18 and end surface respectively 19. Fig. 4 illustrates a plurality of the building blocks 10 OMPI arranged to form a wall in which the rib 11 of a lower block 10 is fitted into the channel 12 of the block 10 above. In use, the building blocks 10 of the first embodiment are laid in courses with the conventional overlapping between the blocks of one course and the blocks of the adjacent course. However, no mortar, cement or "mud" as it is colloquiall referred to, is positioned between the end faces 19 and 21 of the blocks as they are laid. Since masonry blocks do not shrink during manufacture, unlike kiln dried conventional hous bricks, each of the blocks 10 is of a predetermined uniform length. Thus the length of a course of the blocks 10 can always be determined (within the limits of tolerances). In this way the skill of a bricklayer in adjusting the thickness of the vertical motar between adjacent bricks in a course to achieve a desired length is not required. Secondly, because the rib 11 fits into the channel 12 with only a small tolerance gap, the subsequent courses of blocks 10 must follow the lowermost course 30. In this way care in the placement of the blocks 10 is only required in laying the lowermost course 30. Again there is a substantial saving when compared with conventional brick laying techniques since no mortar is located between the upper surface 13 of the blocks 10 of one course and the lower surface 18 of the blocks 10 of the upper adjacent course. The blocks 10 are largely maintained in position by their own weight and the weight of courses above. This applies to all brick or block walls. A weatherproof seal is required between opposite sides o a wall and in a conventional single brick wall this seal is provided by the mortar. In the present arrangement the rib 11 which protrudes into the channel 12 leaves a longitudinally extending gap between the top of the rib 11 and the base of th channel 12. Also this gap communicates with the trough 17. Thus in order to provide a seal in the present arrangement, after each course has been laid, a predetermined charge of liquid mortar is pumped into the aperture 15 of each block 10 in the course. This mortar is forced in both directions along the above described gap and fills the O PI trough 17 . - - - - - In this way a seal is provided both between the upper surface 13 and lower surface 18 and between the end surfaces and 21. Preferably this mortar insertion process is carried out by pumping otar through a flexible tube such as a convention garden hose and the aperture is preferably dimensioned accordingly. An obvious advantage with building blocks of th above described type is that since correct orientation and uniform jointing is always insured, then a minimum of experti is required to obtain a structurely sound and asthetically pleasing result. Thus low cost unskilled labour can be used. The building blocks 10 are also provided with half roun grooves 14 and 16. In a wall or other structure constructed from the building blocks 10 laid with identical orientatio-n, the half round grooves 14 and 16 form an attractive "brick work" pattern on the outer surface of the wall without the ne for skillful finishing of the joints. As seen in Figs. 5 to 9, the masonry building block 30 the second embodiment is also a generally rectangular prism with a rib 31 extending along the upper surface 32 and a channel 33 extending along the lower face 34. A cylindrical aperture 35 extends from the upper surface 32 to the channel 3 and provides and interconnection therebetween. A trough 36 divides the end surface 37 in two and a protrusion 38 extends from the end surface 39. The trough 36 is essentially of rectangular cross-section with a groove 40 o part circular cross-section in the inner most surface 41 thereof and the protrusion 38 has a corresponding groove 42 of part circular cross-section formed in its outer most surface 4 In use, the building block 30 of the second embodiment i laid in the substantially the same manner as described for the building block 10 of the first embodiment supra. However, eac block 30 is laid with the protrusion 38 inserted in the corresponding trough 36 of an adjacent block 30 and accordingly, each block 30 in the course also has the protrusion 38 of the other adjacent block 30 inserted into its trough 36. OMPI The building blocks 30 can be laid with the end surface 37 of one block abutting the end surface 39 of an adjacent block 30, or with a gap between the end surfaces 37 and 39 of adjacent blocks 30, provided that the protrusion 38 of one of the blocks 30 is at least, partly inserted into the trough 36 o the adjacent block 30. Accordingly, the length of a course of the blocks 30 can be adjusted by adjusting the gap between adjacent blocks 30. It will be apparent that if desired, any gaps between th end surfaces 37 and 39 of adjacent blocks can be filled with mortar for example, after the blocks 30 have been laid. A weatherproof seal between the blocks 30 is obtained in the same manner as described before for the first embodiment supra since a cavity for mortar is also provided between the outer most surface of the protrusion 43 and the inner most surface of the trough 41 by the grooves 40 and 42. Figs. 10 to 14 show a corner block 130 for use with the masonry building block 30 of the second embodiment. The corne block 130 has two locating lugs 131 of square cross-section on the surface 132 and a flat end surface 139. In addition, the channel 133 extending along the lower face 134 is terminated before it reaches the end surface 139. The corner block 130 is used where two courses of the building blocks 30 intersect at right angles and form a corner. A building block 30 cannot be used in this applicatio since the rib 31 of a building block 30 in the last course lai will prevent a building block 30 in the next course being laid at right angles thereto. Accordingly, a corner block 130 is used instead of the last building block 30 of each overlapping course since the locating lug 131 nearest the end surface 139 allows the corner block 130 in the next course to be positioned at right angles to the lower block 130. The other locating lug 131 provides for the location of the building block 30 in the course above which also abutts the corner block 130 in the same course. In addition, since the end surface 139 of the corner block 130 is flat, a neat corner at the intersection of two courses of building blocks 30 is always ensured. Figs. 15 to 19 show a T block 230 for use with the building block 30 of the second embodiment. The T-block 230 substantially identical with the corner block 130 described above, except that an additional channel 244 extends across t lower surface 234 and intersects the channel 233 at right angles. The T-block 230 is used where a course of building bloc 30 branches off another course of building blocks 30 at right angles. Again it is not possible to use a building block 30 this application since the rib 31 of a building block 30 in a lower course prevents a building block 30 in course above fro being laid at right angles thereto. Similarily, a corner blo 130 cannot be used since the channel 133 does not extend all the way along the lower face 134 and thus a corner block 130 cannot be laid on, or at right angles to, a lower course of building blocks 30. In practice, a T block 230 is only required at the intersecting end of every second course of a branching wall, for example, since the building blocks 30 are laid in the conventional overlapping manner. Accordingly, the first cour of building blocks 30 of a branching wall, for example, is la abutting the course of blocks 30 from which it branches. In the next course a T block 230 is positioned with the rib 31 o the abutting building block 30 in the branching course, inserted into the channel 233, and with the rib 31 of the adjacent building block 30 in the other course inserted in th channel 244. In this way each alternate branching course is able to overlap the lower course of blocks 30 from which it is branching and the lugs 231 provide for the alignment of the blocks 30 in the subsequent branching and other course. It will be apparent that the T blocks 230 can be laid i substantially the same manner as described for the building blocks 10 of the first embodiment supra, and that a weatherproof seal between the T blocks 230 and the surroundin building blocks 30 is obtained in the same manner as described for the building blocks 30 of the second embodiment supra. In addition to the corner block 130 and the T block 230 described above for use with the building block 30 of the preferred embodiment, other building blocks for specialized application with the building blocks 30 can be produced. For example, an H-block (as shown in Figure 25) with another channel in place of the rib 31 of the building block 30 can be produced for the first course of a structure in which the building blocks 30 are laid with the rib 31 in the lower most position, i.e. upside down to the above described arrangement As seen in Figs. 20 to 23 the masonry building block 350 of the third embodiment is again a generally rectangular prism with a rib 351 extending along the upper surface 354 and a channel 352 extending along the lower face 355. Three cylindrical apertures 353 extend from the upper surface 354 to the channel 352 and provide interconnections therebetween. Troughs 356 divide the end surfaces 357 and 358 in two. Thus, the rib 351 is terminated at each end by the troughs 356 and does not extend to the end surfaces 357 and 358. Four apertures 359 of rectangular cross-section also extend from th upper surface 354 to the lower face 355, two on either side of the rib 351. In use, the building blocks 350 of the third embodiment are laid in substantially the same manner as described for the building blocks 10 of the first embodiment supra. However, th weatherproof seal between the end surfaces 357 and 358 respectively of adjacent building blocks 350 in a course is provided by mortar filling the cavity formed by the two trough 356. In addition, the predetermined charge of liquid mortar i pumped into each of the three cylindrical apertures 353 to provide a better distribution of mortar, particularly when the brick 350 is of relatively large dimensions, for example. The four apertures 359 are provided to reduce the overal weight of the building block 350 and to provide thermal insulation. As seen in Figs. 24 to 26, the masonry building block 41 of the fourth embodiment is also a generally rectangular prism having a rib 411 extending along the lower surface 412 and a channel 413 extending along the upper face 414. A trough 416 divides the end surface 417 in two and extends between the upper face 414 and lower face 412. O PI W1PO In use, the building block 410 of the fourth embodiment is laid in substantially the same manner as described for the building block 10 of the first embodiment supra. However, ea block 410 is preferably laid with the channel 413 uppermost. That is, upside down relative to the arrangement described fo the first embodiment. Liquid mortar is pumped into the gap formed between the rib 411 of building blocks 410 one course and the channel 412 of building blocks 410 in the adjacent lower course via the aperture formed by the trough 416 of one building block 410 a the abutting end face 421 of the next adjacent building block 410 in the same course. Figs. 27 to 29 show a corner block 430 for use with the building block 410 of the fourth embodiment. The corner bloc 430 is generally similar to the corner block 130 for use with the building block of the second embodiment and is used in substantially the same manner as described above for the corn block 130. Figs. 30 to 32 show a T-block 450 for use with the building block 410 of the fourth embodiment. The T-block 450 is generally similar to the corner block 230 for use with the building block of the second embodiment and is used in substantially the same manner as described above for the T-block 230. It will be apparent to persons skilled in the art of building block construction, that the above described bricks can readily be mass produced using known masonry block making techniques. The foregoing describes only four emboidments of the present invention, and modifications which are obvious to thos skilled in the art may be made thereto without departing from the scope of the invention.

Claims: CLAIMS 1. A masonry block having a longitudinally extending rib on one load bearing surface thereof, a longitudinally extending channel on the opposite load bearing surface thereof and slot means communicating between said channel and said rib said rib of one of said blocks being insertable in the channel of a like block. 2. A masonry block as claimed in claim 1 wherein said rib and said channel extend along substantially all the length of said block. 3. A masonry block as claimed in claim 1 or 2 wherein one end of said block has a shaped protrusion extending therefrom and the other end of said block has a correspondingl shaped recess therein adapted to receive the shaped protrusion of a like block when placed in abutting end-to-end relationshi 4. A masonry block as claimed in any one of claims 1 t 3 wherein said slot means comprises an open slot extending between said opposite load bearing surfaces. 5. A masonry block as claimed in claim 4 wherein said slot means further comprises at least one closed slot located intermediate the ends of said block and extending between said rib and said channel. 6. A masonry block as claimed in claim 1 or 2 wherein said slot means further comprises at least one closed slot located intermediate the ends of said block and extending between said rib and said channel. 7. A masonry block as claimed in claim 4 or 5 wherein each of said closed slots is a substantially cylindrical aperture. 8. A masonry block as claimed in any one of claims 4 t 7 when dependent upon claim 3 wherein said recess comprises said open slot. 9. A masonry block as claimed in any one .of claims 1 t 8 wherein at least one interior cavity extends between said load bearing surfaces to reduce the weight and/or materials volume of said block. 10. A corner masonry block for use with the masonry block of any one of claims 1 to 9 wherein said corner masonry OMPI block comprises a pluraltiy of longitudinally aligned locatio lugs on one load bearing surface of said corner block, a longitudinally extending channel on the opposite load bearing surface of said corner block, said channel being closed at on end, slot means communicating between said channel and said o load bearing surface, one of said lugs being insertable into the channel of the block as claimed in any one of claims 1 to 9, and the other of said lugs being insertable in the channel of a like corner block. 11.. A corner block as claimed in claim 10 for use in forming T-intersections with blocks as claimed in any one of claims 1 to 9 wherein said channel is provided with a cross-channel extending between the sides of said corner bloc and all said lugs are insertable in the channel of the block claimed in any one of claims 1 to 9.

Inventors: CREIGHTON ROBERT CRABTREE, DONALDSON DALE BRUCE, CREIGHTON, ROBERT, CRABTREE, DONALDSON, DALE, BRUCE
Applicants: CREIGHTON ROBERT C, DONALDSON DALE BRUCE, CREIGHTON, ROBERT, CRABTREE, DONALDSON, DALE, BRUCE
Application year: 1984
Main classification: E04C1
IPC codes: E04B2