IMPROVED INTERLOCKING BUILDING BLOCK

Abstract: A block (20) of concrete or the like for use in constructing a mortarless wall is provided which includes a spaced parallel pair of upright sidewalls (22,24) having flat bottoms and tops and bearing integral block interlocking connectors (32,33) on their opposite ends. The sidewalls are integrally connected to one or more transverse webs (26) extending from the bottom of the sidewalls to above the tops thereof. Parallel slits (54) may divide the upper end of the web into knock-off portions (56,58,60) for installation of reinforcing bars. Each web (26) has a central concavity (64) in the upper end of at least one opposite side thereof, which concavity slope down into a complimentary central bottom convexity (66). The web tapers in thickness from bottom to top. The concavity (64) and convexity (66) can be triangular, dish-shaped, rectangular, etc. The webs (26) define cells (42,44,46,48,50) in the block when a number of the blocks are vertically stacked in staggered array to form a wall. The webs (26) make point or line contact with each other to interlock and prevent horizontal displacement, while presenting staggered cells and maximum surface area for adhesion to reinforcing concrete poured into the cells.

Description: The present invention generally relates to construction materials and, more particularly, to a mortarless wall block of an improved type. Conventional concrete block walls are laid up by a time-consuming difficult procedure which involves troweling a layer of concrete mortar onto a level concrete or stone base or the like, or the top of a course of previously laid blocks and then setting blocks one at a time in the mortar layer, in each instance also applying mortar to the end walls of each block to join the blocks together. This procedure is continued until the required number of courses are laid. Great care must be taken to keep each course perfectly horizontal and straight. Few people have the skill to carry out such a procedure in a competent manner. Therefore, the cost of such construction is always high. Various types of interlocking blocks have been devised in the past to facilitate block laying. However, most such blocks are very expensive to produce since the interlocking portions, usually grooves and protrusions, normally are sawed into or otherwise fashioned in the blocks after they are initially formed by molding. Moreover, those interlocking blocks in which the interlocking components are initially molded usually are very difficult to mold to acceptably close tolerances. An improved interlocking mortarless building block overcoming these deficiencies is set forth in U.S. Patent No. 3,888,060 issued June 10, 1975, to the inventor of the present invention. That block has been used successfully for a number of years. The block includes flat faced, spaced vertical sidewalls joined by flat faced vertical transverse webs to form a series of cells. The blocks are disposed one upon another in ascending courses in staggered relationship during the construction of a wall. The superposed block cells fully communicate with each other. It has been found that under certain circumstances, additional structural strength is needed and that when wet concrete is poured into the cells and allowed to dry the poured concrete does not always fully adhere to the flat cell walls with maximum strength. Strength is in part due to the surface area of contact between the block walls and the set poured cement. In GB-A-353101 there is described a building brick having two side portions connected by bridging members of triangular cross-section so that the thickness of the bridging members decreases upwardly from the bottoms thereof, and the average thickness at the top is smaller than the average thickness at the bottom of each bridging member. The bridging members do not provide any interlocking function as the tops and bottoms of these members are recessed inwardly of the tops and bottoms of the brick sides. Accordingly, it would be desirable to be able to provide an improved mortarless building block featuring improved adaptability, strength and economy. The design of the block should be such that it can be readily moulded and released from the forming mould with full detail preserved, obviating any subsequent reshaping, finishing, etc. Moreover, the block should be easily strengthened with reinforcing bars, if needed, and be capable of being fabricated in a full array of sizes and shapes. The present invention aims to satisfy all the foregoing needs and accordingly provides an improved interlocking block for a mortarless wall assembly in which a plurality of such blocks are interlocked together to create a substantially continuous planar wall surface having a plurality of stacked linear courses of such blocks, the blocks in each course being interlocked in end to end relation, the blocks in a given one of said courses being in staggered relation to the blocks in the abutting courses in said stack, said block comprising: (a) a pair of spaced, parallel, upright sidewalls having flat top and bottom surfaces, said sidewalls having block-interlocking means on opposed ends thereof; and (b) at least one transverse upright support web spanning said sidewalls and integral and defining a cavity therewith, characterised in that said web has a concavity disposed at the upper end of one of the opposite sides thereof and a complementary convexity disposed at the lower end of said one side, said convexity uniformly sloping upwardly into said concavity, whereby release of said block from a forming mould is facilitated and whereby said web has an increased surface area for improved adhesion to bonding material when poured into said cavity. According to the invention there is also provided an interlocking block for use in a wall construction assembly, said block comprising: (a) a pair of spaced, vertically extending side walls, (b) a first web extending between said side walls, and (c) a second web extending between said side walls, wherein (d) said first and second webs each has a top portion extending above the top of said side walls and a bottom portion not extending below the bottom of said side walls, characterised in that (e) the top portion of each web includes a concavity and the bottom portion of each web has a convexity, (f) said top portion has an average thickness which is smaller than the average thickness of said bottom portion, and (g) the average thickness of each said web decreases upwardly from the bottom thereof. In the preferred embodiment of the invention described in detail herein a plurality of spaced parallel transverse webs extend from the bottom of the side walls to above the top thereof and divide the block into cells. The webs and side walls are tapered from bottom to top in that they have at least one non-vertical upraised side. Specifically, at least one of the two raised sides of the web includes a central concavity at the upper end thereof tapering down linearly or not linearly to a complementary convexity at the central lower end thereof. In case of linear tapering the thickness of the web at the midpoint of that side is about equal to one-half of the combined thicknesses of the web at any two points along that center and equidistant from that midpoint, i.e., above and below that midpoint. Therefore, the mass of the web is balanced, the block has increased stability, the web presents a larger surface area for connection to cement poured into a cell, and the block more easily releases from a single forming mould during its fabrication. The convexities and concavities can be triangular, rectangular, dish-shaped or the like. The webs preferably each have a plurality of spaced slits parallel to the side walls and extending down into the web from the top of the side walls a distance equal or greater than the thickness of a reinforcing bar which could be placed longitudinally in the block. If it is desired to use such bars, the appropriate knock-off portions defined in the webs by the slits are broken away and the reinforcing bars are laid in their place. Certain slits can also separate the upper ends of the web from the side walls and are useful for providing knock-off portions for insertion of two parallel reinforcing bars to compensate for bending stresses in certain structural locations. The blocks can be designed to interlock at their opposite ends by means of tongues and grooves or the like, to form courses. No mortar is needed. The courses may be disposed upon each other without the use of mortar, with the blocks in one course staggered with respect to those of the adjacent courses. The upper portions of the webs of blocks in a given course are positioned to point contact the underside of the webs of the course next above to interlock the blocks and courses together. The cells thereof are in staggered array and exhibit angled walls and a greater surface area for joinder to concrete when the latter is poured into vertically connected cells to strengthen the thus formed wall. Thus, the new improved building blocks are simple, rapid and inexpensive to fabricate and to use and provide a superior wall when laid up in the described manner. Further features of the present invention are set forth in the following detailed description and accompanying drawings. Figure 1 is a schematic perspective view, partly broken away, of a first preferred embodiment of an open ended type of the improved building block of the present invention; Figure 2 is a schematic longitudinal center cross-section of the block of Figure 1; Figure 3 is a schematic perspective view, partly broken away, of a first preferred embodiment of an end or corner type of the improved building block of the present invention; Figure 4 is a schematic longitudinal center cross-section of the block of Figure 3; Figure 5 is a schematic perspective view of a first preferred embodiment of a short end type of the improved building block of the present invention; Figure 6 is a schematic longitudinal center cross-section of the block of Figure 5; Figure 7 is a schematic perspective view of an L-shaped wall during construction thereof, said wall employing the blocks of Figures 1, 3 and 5; Figure 8 is a schematic fragmentary longitudinal center cross-section of the wall of Figure 7; Figure 9 is a schematic perspective view, partly broken away, of a second preferred embodiment of an open ended type of the improved building block of the present invention; Figure 10 is a schematic longitudinal center cross-section of the block of Figure 9; Figure 11 is a schematic fragmentary longitudinal center cross-section of a wall utilizing a plurality of the blocks of Figure 9; Figure 12 is a schematic perspective view partly broken away, of a third preferred embodiment of the open ended type of improved building block of the present invention; Figure 13 is a schematic longitudinal center cross-section of the block of Figure 12; Figure 14 is a schematic fragmentary longitudinal center cross-section of a wall constructed of a plurality of the blocks of Figure 12; Figure 15 is a schematic fragmentary perspective view of a fourth preferred embodiment of the open ended type of improved building block of the present invention; Figure 16 is a schematic fragmentary perspective view of a fifth preferred embodiment of the open ended type of improved building block of the present invention; and, Figure 17 is a schematic fragmentary perspective view of a sixth preferred embodiment of the open ended type of improved building block of the present invention. Now referring, more particularly, to Figures 1-8, a first preferred embodiment of the improved building block of the present invention is schematically depicted therein. Thus, Figures 1 and 2 depict the form of the block which is used between the ends and corners of a wall construction. Figures 3 and 4 depict a long corner form of the same type block, and Figures 5 and 6 depict a short end form of the block. Figures 7 and 8 depict a wall constructed of the blocks of Figures 1-6. In Figures 1 and 2, block 20 is shown. Block 20 can be of any suitable construction material, such as poured set cement, concrete, or can be a so-called cinder block or a block of ceramic clay or other suitable construction material. Block 20 comprises a spaced, parallel pair of vertical sidewalls 22 and 24 interconnected by integral vertical webs 26, perpendicular to sidwalls 22 and 24 and disposed in a predetermined arrangement in block 20. Preferably, each of sidewalls 22 and 24 have flat parallel or tapered opposite faces 34 and 36, flat bottoms 38 and flat tops 40. Opposite ends 28 and 30 of walls 22 and 24 are provided with interlocking means in the form of tongues 32 and grooves 33 for joining blocks 20 lengthwise in a course during laying up of a wall. Webs 26 and sidewalls 22 and 24 divide block 20 into cells 42, 44, 46, 48 and 50 spaced along the length of block 20 and open at the bottom and top thereof and of predetermined size. Webs 26 extend from about bottoms 38 to above tops 40, as shown in Figures 1 and 2. Preferably, webs 26 extend above tops 40 about 10% of the height of block 20. For example, sidewalls 22 and 24 may be about 8 inches high with webs 26 extending about 3/8 inch thereabove. Other dimensions are also suitable. The upper portion 52 of each of webs 26 is preferably divided by four spaced, parallel vertical slits 54 extending down therethrough and totally across the thickness of portion 52 parallel to sidewalls 22 and 24 so as to form three separate top break-off sections 56, 58 and 60 in each portion 52. Central section 58 usually is wider than side sections 56 and 60. Slits 54 extend down in portion 52 a sufficient distance below tops 40 so that each of sections, 56, 58 and 60 is deep enough to accommodate, when broken off, the full thickness of a reinforcing bar (not shown) which is adapted to extend longitudinally in block 20 below tops 40. It will be understood that the desired number of the same type of break-off sections can be removed from the particular webs 26 involved in block 20 so as to accommodate the full length of such a bar. Normally, section 58 is not used as a break-off section. Instead, section 58 and portion 62 lying below section 58 and extending to the bottom of each web 26 is specially configured, so as to include a generally triangular concavity 64 in section 58 and a complementary generally triangular convexity 66 in portion 62, which grades thereinto. Each triangular configuration has curved sides. Concavity 64 and convexity 66 appear in only one side 68 of each web 26, the opposite side 70 thereof being flat and vertical (not shown) or slightly sloped toward portions 66 and 68 from the bottom surface 74 towards the upper surface 76 (as shown in the figure) to form a double taper to web 26 between the bottom surface 74 and upper surface 76 which provides an improved disengagement of the block from its forming mold. This is more easily seen in Figure 2. Thus, at the center midpoint 72 along the length of side 68 of each web 26, neither concavity 64 nor convexity 66 is present. The thickness of each web 26 at point 72 (the midpoint of the center longitudinal cross-section of web 26) is equal to one-half the sum of the thicknesses of the web at any two points equidistant from point 72; that is, above and below point 72 and along the center longitudinal cross-section. In effect, each web 26 uniformly or non-uniformly slopes from concavity 64 to convexity 66 so that the bottom 74 of each web 26 is thicker than the top 76 thereof at the center of side 68. This improves the stability of block 20 and facilitates its release from an open bottomed mold. This also increases the total surface area of web 26 for improving its adhesion to reinforcing cement which may be poured into cells 42, 44, 46, 48 and 50. It will be noted that different ones of webs 26 have their web sides 68 differently oriented, as shown in Figure 1, i.e,. facing away or toward each other, as more particularly referred to below. Block 20 is simple, rapid and inexpensive to mold in a single operation from a single mold and is easy to use in constructing a wall. Figure 3 and 4 schematically depict a corner form of the block of the same embodiment as that of Figures 1 and 2. Thus, block 20′ is shown which is similar to block 20. Components thereof similar to those of block 20 bear the same numerals, but are succeeded by the prime sign "′". Block 20′ includes sidewalls 22′ and 24′ and webs 26′, one of which is shown in Figure 3. Block 20′ also includes an end wall 80 interconnecting sidewall 22′ and 24′ and a pair of spaced vertical supports 82 and 84 integrally connected to sidewalls 22′ and 24′, respectively, and disposed in space 86 between wall 80 and web 26′. One tongue 32′ and one groove 33′ are present in end 30′ of each of sidewalls 22′ and 24′. Corner block 20′ is used in a wall assembly, such as is shown in Figures 7 and 8. Figures 5 and 6 schematically depict a short end form of the block of the same embodiment as that of Figures 1 and 2. Thus, Block 20″ is shown which is similar to block 20 and block 20′. Components thereof similar to those of block 20 and/or block 20′ bear the same numerals but are succeeded by the double prime sign "″". Block 20″ includes short sidewalls 22″ and 24″, end wall 80″ and vertical supports 82″ and 84″, as well as tongue 32″ and groove 33″, but no transverse web. Block 20″ is used in a wall assembly, such as is shown in Figures 7. Figure 7 schematically depicts an L-shaped wall 90 laid up very easily, rapidly and accurately without professional labor and without mortaring by using blocks 20, 20′ and 20″ to form stacked horizontal courses 92. It will be noted that blocks, 20, 20′ and 20″ are interconnected one by one lengthwise by their respective tongues and grooves so that no mortar whatsoever is needed to lay up courses 92. Courses 92 are laid up with blocks 20, 20′ and 20″ of one course offset lengthwise with blocks 20, 20′ and 20″ of the two adjoining courses (Figure 7). Moreover, courses 92 are easily kept straight and level because tops 40 and bottoms 38 are flat and horizontal, the bottoms 38 of one course 92 resting directly on the tops 40 of the next lower course 92. In addition, lateral displacement of the respective blocks 20, 20′ and 20″ is prevented due to the fact that upper portions 52 of the webs 26 and 26′ of blocks 20 and 20′ in a given course 92, as well as supports 82 and 84, 82″ and 84″ project upwardly into the respective cells of the blocks in the next above course 92. Those projecting webs 26 and 26′ abut by point contact the lower portions of webs 26 and 26′. This is shown in those blocks in the upper course providing positive alignment of the courses 92 containing blocks 20, 20′ and 20″. M oreover, the cells in blocks 20, 20′ and 20″ have extended surface area due to the angling of portions of webs 26 and 26′ so that when wet aggregate (see Figure 8 at the right side of the Figure) is poured thereinto to bond wall 90 together, that aggregate more readily and strongly bonds thereto, and wall 90 has a resultingly increased strength. Figures 9-14 depicts further embodiments of the improved block of the present invention which materially differ from blocks 20, 20′ and 20″ only in regard to the number of webs employed and their particular spacing of such webs. The overall shapes of such webs are generally the same as webs 26 and 26′. The relative dimensions of the various webs depicted in Figures 9-14 can be easily compared with webs 26 and 26′ by reference to proportion reference indications of component portions marked L, A1, A2, B1, B2, and C in Figures 9-14 and L, A1, A2, B1, B2, C1 and C2 in Figures 2, 4 and 6. The blocks of the present invention follow the same proportional relationships as are embodied in the formulas set forth in U.S. Patent No. 3,888,060. Thus, L (length) = B1 + B2 +A1 + A2 + C1 + C2 as described in the patent. It will thus be seen that in Figures 9-11 and block 20a is substantially identical to block 20, except it contains only two webs 26a, rather than four webs, as in block 20. Block 20b shown in Figures 12, 13 and 14 has three webs 26b, each of which is similar to webs 26 and 26′. Figure 14 schematically depicts a wall laid up using blocks 20b. Figures 15, 16 and 17 depict blocks of the present invention which differ from block 20 only in the particular shape of center portion of the webs thereof. Thus, in Figure 15, block 20c is shown which is identical to block 20 except that each web 26c has a central dish-shaped top concavity 64c sloping downwardly into a bottom dish-shaped convexity 66c. Concavity 64c and the convexity 66c are located in, respectively, sections 58c and 62c. The thickness of web 26c along its center longitudinal cross-section follows the same rules generally as specified for web 26. Web 26c has increased surface area, as does web 26. Figure 16 depicts block 20d identical to block 20′ in all respects except that each web 26d thereof has a rectangular concavity 64d sloping down and blending into a rectangular convexity 66d, and except that the two most central of slits 54d extend only part of the way through the thickness of web 26d, so that web 26d is strengthened. Web 26d also has increased surface area for improved adhesion to poured aggregate. Figure 17 depicts block 20e which is identical to block 20 in all respects except that each web 26e thereof has a dish-shaped concavity 64e and a dish-shaped convexity 66e in each of its two sides 68e and 70e, and except that web 26e contains no slits 54 at all and thus is relatively stronger. The thickness of web 26e along its center longitudinal cross-section follows the rules previously described for web 26. Accordingly, web 26e has substantially increased surface area. Various other modifications, changes, alterations and additions can be made in the improved building block of the present invention, its components and their parameters. All such modifications, changes, alterations and additions as are within the scope of the appended claims form part of the present invention.

Claims: An improved interlocking block (20) for a mortarless wall assembly in which a plurality of such blocks are interlocked together to create a substantially continuous planar wall surface having a plurality of stacked linear courses of such blocks, the blocks in each course being interlocked in end to end relation, the blocks in a given one of said courses being in staggered relation to the blocks in the abutting courses in said stack, said block comprising: (a) a pair of spaced, parallel, upright side walls (22, 24) having flat top and bottom surfaces (38, 40), said side walls having block-interlocking means (32, 33) on opposed ends thereof; and, (b) at least one transverse upright support web (26) spanning said sidewalls and integral and defining a cavity therewith, characterised in that said web (26) has a concavity (64) disposed at the upper end of one of the opposite sides (68) thereof and a complementary convexity (66) disposed at the lower end of said one side (68), said convexity uniformly sloping upwardly into said concavity, whereby release of said block from a forming mould is facilitated and whereby said web has an increased surface area for improved adhesion to bonding material when poured into said cavity. The improved block of claim 1, wherein said web concavity (64) and convexity (66) are disposed along the center of said one side (68) and wherein the thickness of said web (26) at the midpoint of the length of said side center is about equal to one-half the combined thickness of said web at any two equidistant points along said side center above and below said midpoint. The improved block of claim 1 wherein said web (26) uniformly tapers down in thickness from the bottom to the top thereof to facilitate release of said block (20) from a forming mould during fabrication of said block. The improved block of claim 1, 2 or 3, wherein said web (26) extends from the bottom (38) of said side walls (22, 24) to above the top (40) of said side walls, that portion of said web above said side walls comprises locking means, and a plurality of said webs (26) are spaced parallel to each other in said block (20) and about perpendicular to said side walls. The improved block of claim 4, wherein said webs (26) are positioned such that when a plurality of said blocks (20) are disposed in staggered stacked relation to form a wall assembly (90), said webs intersect each other to make point contact with each other for interlocking said blocks against horizontal displacement. The improved block of claim 5 wherein said webs (26) divide said block (20) into a plurality of cells (42, 44, 46, 48, 50) and wherein when a plurality of said blocks are disposed in staggered stacked relation to form a wall assembly (90), adjoining stacked ones of said cells are in staggered array with each other to provide increased surface area for the adhesion of reinforcing material to said webs when poured into said cells. The improved block of any one of claims 1 to 6, wherein the upper portion (52) of said web (26) is divided by parallel slits (54) into a plurality of knock-off portions (56, 58, 60) which can be removed to permit the addition of longitudinally extending reinforcing bars to said block, said slits extending down into said web a predetermined distance at least about equal to the thickness of said bars to be added to the block. The improved block of claim 7 wherein said slits (54d) extend only partially through the thickness of said web upper end in a direction parallel to said side walls (22, 24) whereby the strength of said web (26) is improved. The improved block of claim 7 or 8, wherein two of said slits (54) separate said upper end of said web from said side walls and are adjacent said side walls. The improved block of claim 9 wherein there are four of said slits (54) in said web parallel to said side walls (22, 24) and wherein there are three of said knock-off portions. The improved block of any one of claims 1 to 10, wherein each of said two opposite sides of said webs (26) has a concavity and complementary convexity. An interlocking block (20) for use in a wall construction assembly, said block comprising: (a) a pair of spaced, vertically extending side walls (22, 24), (b) a first web (26) extending between said side walls, and (c) a second web (26) extending between said side walls, wherein (d) said first and second webs each has a top portion (52) extending above the top (40) of said side walls and a bottom portion (62) not extending below the bottom (38) of said side walls, characterised in that (e) the top portion of each web includes a concavity (64) and the bottom portion of each web has a convexity (66), (f) said top portion (52) has an average thickness which is smaller than the average thickness of said bottom portion (62), and (g) the average thickness of each said web decreases upwardly from the bottom thereof. The block of claim 12, wherein the concavities (64) in the top portions of said first and second webs face one another. The block of claim 12 or 13, wherein the convexities (66) in the bottom portions of said first and second webs face one another. The block of claim 14, wherein said concavities (64) and convexities (66) in each web are complementary to one another. The block of any one of claims 12 to 15, wherein the right side of each web is a mirror image of the left side of each web. The block of any one of claims 12 to 16, wherein the thickness of the top and bottom portions (52, 62) of each web varies continuously along their lengths. The block of any one of claims 12 to 17 wherein the intersection between a given plane extending perpendicular to a web (26) and the front face (68) of said web defines a first straight line. The block of claim 18 wherein the intersection between said given plane and the rear face (70) of said web (26) defines a second straight line. The block of claim 19 wherein said straight lines are not parallel to one another. The block of any one of claims 12 to 20, wherein the upper half of each web (26) has a concavity (64) therein and the lower half of each web has a complementary convexity (66). The block of any one of claims 12 to 22 wherein said upper portion (52) has a plurality of vertically extending slots (54) therein defining knock-out portions (56, 58, 60). The block of any one of claims 12 to 22, wherein the convexity (66d) has the shape of a wedge tapering in thickness upwardly from the bottom of the web. The block of any one of claims 12 to 23, wherein the concavity (64) of each web is arranged to receive the convexity (66) of a web of another block positioned above said block in a wall structure assembly, whereby to interlock said blocks relative to one another.

Inventors: HAENER, JUAN
Applicants: HAENER, JUAN
Application year: 1986
Main classification: E04B2
IPC codes: E04B2