INTERLOCKING SYSTEM FOR BUILDING WALLS

Abstract: Construction of an aligned wall of building blocks wherein superposed blocks (10, 11) are connected by means of small metal balls (3) in semicircular openings (2) wherein compensation is made for variations in height of the blocks by drilling said openings to a depth which is dependent upon the height of said blocks and wherein compensation is made for face perpendicularity by providing aligned top V grooves (5) in which is placed a reenforcing metal rod (6) so that an aligned row of said blocks can be manipulated until the most optimum face perpendicularity is obtained to result in a tolerance between said balls and the edges of said openings of .001 to .002 of an inch.

Description: •—I ι*NmT*Em—R—L—_O__C_K_!i—I—N—fOm—mS^Y^mSTEmMmχ—F5 ~O—R——~B—U——I—L~—D~I—~N—G~——W~ m A~L~—L~S~ r This invention relates.to building a wall and its foundation with conventional building blocks incorporating a system or aligning said blocks into a vertically and horizontally straight wall. The conventional concrete block has been recognized as the least expensive construction material, at less than one cent per pound. Furthermore, the concrete block has also been recognized as the most versatile construction material for being firesafe, sound deadening and absorbing, and decorative, and for being readily available all over the world, being virtually maintenance free and indestructible, and being termite safe and almost tenant safe. Today, it is possible to produce 25,000 concrete blocks every 8 hours with the new machines in the market place. So far, production is highly mechanized and economically productive. Nevertheless, the installation methods have remained the same for many, many years dependent upon installation by highly skilled labor. Attempts have been made to mechanize the installation by using cheap unskilled labor. One such attempt is the use of odd shaped interfitting blocks but this system shoots the cost of the per square foot of wall above the $3.00 level. Another attempt is shown in the Schlo ann Patent No. 4,228,628 who shows the use of spherical metal balls situated in aligned hemispherical openings between two superposed blocks. However, this system of alignment has not been commercially viable for use because not only are the balls ill-fitted but also there is no means present to assure alignment of the balls in their grooves to compensate for variation in height of the blocks and for variations in perpendicularity of the faces. Even the new block-producing machines cannot make the blocks accurate to less than .050 of an inch in height. Because of this, the accepted tolerance in block height is plus or minus 1/16 of an inch. Consequently, this variation in height in extreme instances can be up to 1/8 of an inch. Some means must be provided to compensate for this variation in height. Therefore, the main object of this invention is to employ means to overcome this variation in height of the blocks. Another object of this invention is to compensate for the variations in face perpendicularity of the blocks. A further object of the invention is to provide a means for an unskilled worker to allow him to construct an accurately positioned and levelled first row of building blocks. A further object of this invention is to locate the metal balls 7.875 cm. apart to make sure of sufficient holding power in connecting the superposed blocks and to obtain an accurate lengthwise spacing of 15-750 inches (40 cm.) between blocks. With the foregoing objects in view together with such other objects and advantages as may subsequently appear, this invention resides in the parts and in combination, construction and arrangements of parts hereinafter described and claimed and illustrated by way of example- in the accompanying drawings in which: FIG. 1 is a perspective view of a 3-core building block, with the inclusion of a medially positioned rod and an exploded section view of the V-groove, FIG..-2 is a front elevation view of a cross-section of 2 superposed building blocks in alignment, FIG. 3 is a front elevation view of a cross-section of 3 building blocks in broken joint relation to each other, FIG. is a top cross-sectional view of a 2 core block with an offset rod nearer the front face of the block, FIG. 5 is a perspective view of a leveling means, FIG. 5a is an exploded cross-section of a ball and the channel opening for the ball, FIG. 6 is an amplified cross-section view of a sheet metal angle with its leveling screws, FIG. 7 ' is a perspective view of a modified leveling channel for floor or roof slab use, FIG. 8 is a cross-section of Fig. 7 showing the use of metal bands and leveling screws, FIG. 9 is a perspective view of 2 reinforced masonry wall sections showing a window and a door opening and an exploded view of the leveling plates, FIG. 10 is a cross-section view showing a wall footing frαa ground to floor slab, FIG. 11 is a cross-sectional view of 3 superposed blocks to show the relative positioning and clearances between the openings and the balls, and FIG. 12 is a cross-sectional view showing the inter¬ connection for a door frame and building end block. OMPI ^5-W. WIPO " → * Re erring to the drawings, in Fig. 1 there is shown a 3 core building block which has been machined to compensate for variations in height of the block so as to provide a tolerance of .002 of an inch between opposed edges of the openings. The block bottom and top faces are irregular and coarse. In addition, the side and -bottom or top faces vary in perpendicularity to each other. The openings are machined into the top and bottom faces at the same time. Εiese openings are machined in relation to the plane passing through its lowest contact point with its opening bottoms lying in a plane that is accurately perpendicular to the block side planes. The depth of these top openings are machined to a specific limit in relation to the top of the block (i.e. the height of the block). Thus, when conventional blocks measuring βin. x 8in. x iδin. are to be used, these blocks are actually 5 5/8 inches wide, 75/8 inches long, but vary from 73/4 inches to 7 5/8 inches in height. In using 3/8 in. spherical metal balls, these openings are accurately machined, to be within .002 of an inch tolerance, thus the superposed blocks will be perpendicular and parallel to each other. Such accuracy is attainable when measured between planes passing through the center of the balls. These machined openings are made in the building blocks with such accuracy as to obtain a tolerance less than .010 of an inch for 10 foot lengths and heights. It is noted that the depth of the drilled opening is dependent upon the specific height of the block. In Fig. 1, the metal ball 3, having a 3/8 inch diameter, is placed in the specifically machined opening 2 while metal rod 3 is deposited in machined V-groove 5. Such a rod is ■utilized to ' assure means for adjusting the misalignment of superposed blocks due to particles of dust, sand or stone accidentally dropped into the openings and which particles are then crushed against the ball so the block falls into its proper place. T5ιe balls may be composed of steel bearings or resinates. The lengthwise distance between adjoining beads equal 1/2 the modular length of the blocks and the crosswise distance between the lines of adjoining beads is 1.180 inches smaller than the block width. These tolerances are critical and the result of numerous trial and error experimenting tβ determine such optimum tolerances. Fig. 2 shows 2 superposed blocks 10 and 11 with machined depth openings 2 in which are located beads 3. Fig. 3 shows 2 lower blocks 14 that are superposed in staggered arrangement, block 15 showing specifically machined openings 2 in which beads 3 are placed. Usually 4 staggered openings are used for a 3 core block but, if larger, the numer would increase, if smaller, it would decrease. To assure against misalignment of the balls in their machined openings, a standard length of reenforcing steel rod β is manipulated so that the top machined openings will fit snugly on the top half of the balls. The advantage of using a steel rod to adjust for misalignment is that such a rod being composed of metal can also serve as a reenforce ent means. In many instances, when using cored building blocks, it is desirable to keep the cores free for later insertion of wires ~_ lKET * OMPI ~ iper &NAΎ\ _ and pipes, m Fig. 4, there is shown a 2 core bui±αing D-LUCΛ. in which a machined V-groove is offset close to the face of the block. vThe -kind of beads that can be used include commercially available steel ball bearings, hollow or solid, and stress- bearing resinates. The building blocks can be 2 or 3 core and can be of any size or shape such as lintel blocks, building blocks or blocks made of bricks, glass, resin or cellulosic composition. When machining the hemispherical openings, opposed - conical drills are so located as to provide all the openings needed on each block at one drilling time which provides « openings that result in a maximum tolerance of .002 inches both in depth and the spacing between the opening edges. These openings should be 7.875 inches apart. m Fig. 5 9 there is shown a leveling means comprising a steel channel 19 with one of several steel angles 22 used to support the channel and the first row of blocks of the wall and the wall footing 25 and 26 to be erected. There are punched openings 21 in the channel to match block cores and punched openings 20 for insertion of balls and punched grooves 24 (.065 of an inch x 1/2 inch) to serve as attachment means for the steel angles 22. Fig. 5a illustrates the close tolerance between the opening 20 and the ball 2 with the opening being 11/32 inches and the ball is 3/8 inches. Two steel angles, as shown in Fig. 6, are connected to the sheet metal channel or each block. By adjustment of ' leveling screws 23 at the steel angles, each first row block when placed on this leveling channel is leveled both crosswise and lengthwise. OMPI • ^Λ'ATIO^? In Fig. 6, there is a clear showing of the channel 19 with locked in steel angles 22 and the relation of the blocks supported by..said channel. In Fig. T, there is shown a variation of the metal channel leveler adapted for use over a floor or a roof slab. Tϊiis channel member 19A has shorter depending sides having a narrow ledge 23B through which a plate 23C is attached by means of machine screws 23A which being threaded can be used for leveling means. In Fig. 8, the metal channel 19A which is a cross- section taken of Fig. 3 to clearly show one block in width and shows bead 2 in opening 20 with 2 opposed leveling screws. For each block 4 leveling screws will be used. In Fig. 9 9 there is shown 2 adjoining reinforced masonry wall sections which uses this system of building. The wall at the left shows partially built walls over an existing floating slab 31 using standard 3 core blocks 35 and channel 19. The wall at the right and its adjoining section of the left wall are built at the same time that footing 30 is built, using standard 3 core blocks and end block 35 which is provided with groove 36 measuring 1/9 inch x 1/2 inch for insertion of window and door frames having side males. There are also leveling channels 19, steel angle 22, leveling screws 23 and reinforcing alignment faces 6 with standard lintel blocks 40 and reinforced concrete columns 39. Side male window frames and door frames can be slid into the female grooves 36. In the exploded section, there is shown steel channel 19, angle iron 22 and leveling screws 23 and OMPI misalignment means rods 6 also serving as reenforcement. Any ordinary unskilled worker can with this disclosed system produce the structure of Fig. 9 which provides a load bearing wall capable of supporting more than 4000 lbs. per lineal foot when using standard 6 inch blocks filled at the end cores with reinforced concrete 39. Die rods 6 and 6A are 3/8 of an inch in circum erence and when completed, the structure yields 4000 lbs. per lineal foot of wall loads. These loads are fully supported by columns 39, with the perfectly aligned balls 2, and the reinforced columns which are spaced 15.750 inches (40 cms. ) apart are kept ' to a minimal slenderness ratio yet increasing its load bearing characteristic of the column to a maximum. The resultant wall is so closely aligned that its faces can be coated with a thin layer 50 of an aqueous mixture of coarse sand, pea gravel and cement with a higher than normal water ratio to provide for the best chemical setting, since the porous characteristic of the blocks will absorb the excess of water and later .will.yield the additional water required in the final setting of the concrete. This thin coating may be applied with a brush by unskilled labor to the final texture and color desired at a fraction of the cost of mortar or gypsum plastering by highly skilled labor. Leaving the 3 cores of the building blocks open by offsetting the misalignment bar provides space for the location of electric, plumbing, refrigeration, and air conditioning and tubing making it easy to open the block cores on either side of the wall. This is very important considering the present and future developments in heating and air conditioning. OMPI ^ WIPO >J føto A τιo* Underground construction, which has about a 75* Fahrenheit temperature, will now have access to the core blocks for the multiple tubing .needed. Based on the social and economical advantages of this system, the College of Agriculture and Mechanic Arts of the University of Puerto Rico has endeavered in the investigation and testing of this complete system with very favorable results, has constructed 23 wall specimens for ultimate tests for seismic, wind, and hurricane loads at a cost of thousands of dollars. In Fig. 10, there is shown a cross section view of 3 superposed blocks comprising a wall footing from ground 40, where stakes 41 are driven into the ground, form board 42 nailed to the stake 41 and support board 43 nailed to the form board 42. Resting on this support board is channel member 22 having channel leveler 19. Set screws 23 are used to level said channel member. Balls 3 are placed in openings 2 for superposing blocks 46, 47 and 48. Concrete 45 is poured through and around block 46 to fix it in place to foπa footing 4 . in order to provide a level floor, part of blocks 47 and 48 are removed and the floor slab of concrete 49 is inserted. In Fig. 11, the height tolerances are more clearly shown of the 3 superposed blocks of Fig. 10. From the center line of the balls 3, irregardless of the block heights which vary from 75/8 inches to 7 3 inches, the distance from center line to center line of the balls is 7.875 inches (20 cms.) + .002 inches in tolerance. It is possible to obtain such close tolerances only because of the precise machining of the openings during drilling. In Fig. 12, there is shown a means to connect one type of a door frame to an end block. Corresponding grooves 51 are formed in an end block 35 so that steel plate 37 can be -used as' a connector. This connection when used with caulking 54 between the 2 members will secure the door frame 50 without the need to use any other supports. To sum up, the novel leveling building system when constructing a wall with unskilled labor including the laying of a level footing is the first system that makes the ball connection system between superposed blocks commercially viable. This system solves the problem of variations in height of ordinarily manufactured building blocks as well as the variations in the perpendicularity of the aligned blocks in the wall. An added novelty includes the use of a steel plate to connect a door frame to a standard end block. It is not intended to limit this invention to the details defined in the claims which follow since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The gist of this invention can enable others to apply current knowledge and adapt it for various applications without omitting features that, from the standpoint of the prior art, fairly constitute essential characteristics of the generic or the specific aspects of this invention. OMPI

Claims: AMENDED CLAIMS [received by the International Bureau on 05 September 1984 (05.09.84); new claim 19 added; other claims unchanged] Claim 19. In the- COnstruetion of an essenially accurately aligned ^ wall of building-blocks by using small metal balls to connect 2 superposed blocks having semicircular opposed ' openings into which said balls fit wherein to compensate for. variations in height of said- blocks, said openings are drilled to a depth dependant: upon the height:, of: the block and wherein 2 superposed rows of blocks are provided with said blocks having aligned top V grooves into ** which is placed an elongated reenforcing rod which can be manipulated to compensate- for variations in planar perpendicularity of the faces of said blocks to result in a tolerance between sai balls and the edges * of said openings of ,001 to .002 o an inch.

Inventors: NEGRON-CRESPO JORGE L, NEGRON-CRESPO, JORGE, L.
Applicants: NEGRON CRESPO JORGE L, NEGRON-CRESPO, JORGE, L.
Application year: 1984
Main classification: E04C1
IPC codes: E04B2