Method and apparatus for erecting a glass block wall

Abstract: A glass block wall (10) has a frame member (12) that frictionally engages the glass block (14) adjacent thereto. A continuous flexible spacer member (16) extends along the horizontal end walls of the glass blocks in each course. Separate vertical spacer members (46) abut the adjacent vertical end walls of the glass blocks and a filler material is (18) positioned in the recess formed between the edges of the adjacent glass blocks (14) and the edge of the spacer member (16). The spacer members (16) have a configuration to align the glass blocks (14) in the wall and to stabilize each of the glass blocks in the wall.

Description: This invention relates to a method and apparatus for erecting a wall and more particularly to a method and apparatus for erecting a glass block wall within a frame member with spacer members positioned between the end walls of adjacent glass blocks. Glass block walls have been erected in the past. The conventional method for erecting such walls include the use of mortar between the horizontal and vertical end walls much in the same manner as a conventional brick wall. Separate spacers have also been positioned between the horizontal end walls of the glass blocks. As disclosed in United States Patents 3,422,588 and 2,281,524 and French Patent 1,401,279, the end walls of the blocks have also been modified to provide mating surfaces with dove-tall type mortar receiving portions, other types of recessed portions and upwardly extending rail-like shoulder portions. United States Patent 4,058,943 discloses a glass block panel with a plurality of rigid interlocked spacers which form a grid-like structure surrounding the glass blocks. United States Patent 2,318,362 discloses a wall structure where the glass blocks have rib-like grooves in the end walls that are positioned on separator strips so that the wall structure may be disassembled without damaging the glass blocks. United States Patent 4, 648, 226 discloses a glass block with a modified configuration of the end walls. The modified glass blocks are arranged to be positioned in a frame having a mating configuration to maintain the glass blocks in a wall structure. German Patent Publication DE 3304971 Al discloses a method of fabricating a glass block wall using glass blocks of generally rectangular configuration and including a spacer member between the glass blocks in assembly, the ends of which have rib portions for supporting the glass blocks. German Patent Publication DE 3328791 Al, which is related to the above identified German Patent Publication, discloses a similar structure. The Architectural Design Division of United Ceramic Tile, 156 Fifth Avenue, N.Y, N.Y. published a brochure that discloses the Tabiluz System which includes a frame and spacers fabricated from a rigid polyvinyl chloride. The joint appears to be a spacer having an elliptical configuration in section with inclined side walls that permit limited compression of the spacers. The spacers are wedged between the glass blocks during erection of the wall. Steck Fix-Saverbat of Grandvillers, France published a brochure illustrating a frame having spaced vertical rises secured to the frame with the glass blocks positioned therebetween. Nylon spacers are positioned between the glass blocks to ensure evenness of the joints. There is a need for a glass block wall that may be quickly assembled with a minimum of components and not require the modification of the shape of the end walls of conventional glass blocks. According to one aspect of the invention there is provided a glass block wall comprising a plurality of glass blocks mounted in a frame, said glass blocks each formed from a pair of hollow glass block halves with rectangular edge portions fused to each other and forming a raised continuous bead therebetween, said glass blocks having a generally rectangular configuration with end walls and side walls forming edge portions therebetween, said glass blocks having a preselected thickness between said side walls, said raised continuous bead formed in said vertical and horizontal end walls intermediate said edge portions, said glass blocks being positioned in abutting relationship with each other with spacer members positioned between adjacent end walls of said glass blocks, said spacer member having a body portion with longitudinal side edge portions and a transverse dimension substantially equal to the distance between the block edge portions of opposite side walls and smaller than said preselected thickness of said glass block in order to provide a channel shaped recess portion between adjacent block edge portions and the side edge portions, each said side edge portion forming a rib projecting above and below said body portion, the rib having an upper shoulder portion and a lower shoulder portion provided with flat surfaces abutting the edge portions, characterised in that said spacer member is provided with a pair of spaced intermediate rib portions forming an upper recessed portion and a lower recessed portion extending longitudinally on said spacer member for respectively receiving a said raised bead of adjacent ones of the glass blocks thereby to align and stabilise adjacent glass blocks of the glass block wall. According to another aspect of the invention there is provided a spacer member for positioning between adjacent blocks of a glass block wall, each glass block having a beaded portion formed between two fused halves thereof, the spacer member comprising, an elongated body portion formed from a flexible plastics material having sufficient strength to resist deformation under load, said body portion having a top surface, a bottom surface and side edge portions forming a rib projecting above and below said body portion, the rib having an upper shoulder portion and a lower shoulder portion provided with flat surfaces for abutting outer edge portions of adjacent blocks, the spacer member having a width corresponding substantially to the distance between the opposite outer edge portions of the block, characterised in that said top surface of the body portion has a pair of spaced parallel longitudinal ribs intermediate the respective ends of the spacer member and forming a recess portion therebetween for receiving the bead of a glass block, formed by fusion of glass block halves to form the glass block, mounted on the spacer member, said bottom surface having a second pair of spaced parallel longitudinal ribs in aligned relation with said first pair of ribs and forming a lower recess portion for receiving the said bead of the glass block adjacent thereto, thereby to align and stabilise adjacent glass blocks in the glass block wall. The invention will now be described by way of example with reference to the accompanying drawings wherein: Figure 1 is a fragmentary perspective view of a portion of a glass block wall; and Figure 2 is a view in section of a pair of glass blocks in the glass block wall illustrated in Figure 1 with the spacer member positioned therebetween and the silicone caulking along the edges of the block. Figure 3 is a top plan view illustrating the frame member and the horizontal spacer member broken away to illustrate a vertical spacer member and the silicone caulking. Referring to Figure 1, there is illustrated a glass block wall generally designated by the numeral 10 that includes a frame member 12, a plurality of glass blocks 14 with spacer members 16 positioned therebetween and a silicone caulking material 18 positioned in the joints between the glass blocks 14. The frame member 12 is preferably fabricated from a rigid polyvinyl chloride material although the frame member 12 may be fabricated from any other suitable material which provides a rigid frame for the glass blocks. As illustrated in Figure 3, the frame member 12 has a body portion 20 and a pair of flanged end or edge portions 22 and 24. The flanged portions 22 and 24 are so dimensioned that they receive a glass block therebetween and are inwardly bent relative to the body portion 20 so that the blocks will snap into position within the frame 12 and be frictionally engaged therein. The glass block abuts the front edge of the body portion 20. Preferably, the frame 12 is made from a rigid polyvinyl chloride that will yield sufficiently to permit the glass blocks 14 to be snapped into place within the frame member and has sufficient rigidity for the flanges 22 and 24 to frictionally retain the glass block members therein and provide rigidity for the glass block wall 10. The frame body member 20 has a plurality of apertures 26 therein arranged to receive wood screws or other fastening means to fasten the frame member 12 to a rigid adjoining structure. The frame member 12 fabricated from the channel-shaped plastic members has a vertical member 28 and a horizontal member 30 suitably joined to each other to form a corner 32. It should be understood that the frame member may also have another horizontal top member and another vertical member to form a generally rectangular frame. It should be understood, however, that the glass block wall may be fabricated with a portion of a frame that may be positioned in an appropriate opening within a structure. The glass blocks 14 are conventional glass blocks having a generally rectangular configuration which are formed by fusing a pair of glass block halves to each other to form the hollow glass block. The glass blocks have a configuration as illustrated in Figures 2 and 3 with a pair of side walls or faces 32 and 34 with four peripheral vertical and horizontal end walls 36 which are joined to the side walls or faces 32 and 34. The glass block end walls 36 have the same configuration, however, in certain types of blocks which are rectangular with one dimension greater than the other, the area of the longer walls is greater than the area of the shorter vertical walls. As previously discussed, the glass blocks are formed by a glass molding process where molten glass is poured into a mold and one-half of the block is formed in the mold. Thereafter two of the block halves are positioned with the free edges abutting each other and are subjected to heat to melt the glass along the edges and fuse the two block halves to each other to thus form a unitary, hollow glass block. The glass block end walls 36 have a raised portion or bead 38 which extends around the periphery of the block and is formed by the fused joint between the block halves. As illustrated in Figure 2, the walls 36 have an inclined portion 40 and a rounded edge portion 42 with the edge portion 42 extending slightly below the raised portion 38. The spacer member 16 positioned between the walls 38 of the glass blocks 14 is illustrated in detail in Figure 2. The spacer member 16 is preferably fabricated from a suitable plastic material such as a flexible polyvinyl chloride having a 65 durometer hardness and is preferably fabricated from a clear polyvinyl chloride material. It should be understood that other flexible materials having the desired rigidity to support the wall without substantial deformation may also be used. The spacer member 16 is fabricated in elongated lengths and may be stored in rolls 44 as illustrated in Figure 1. The configuration of the spacer member 16 as later discussed is formed by extruding the polyvinyl chloride through an appropriate die to provide the desired configuration. Segments 46 of the spacer 16 which are positioned along the glass block vertical walls 36 are cut to a preselected length from the extruded spacer member to have a dimension where the spacer 46 will be in substantial juxtaposition with and preferably abut the continuous horizontal spacer 48. The intersection of the vertical spacer 46 and the continuous horizontal spacer 48 is illustrated in Figure 1 along the first course of the glass blocks 14 in the glass block wall 10. Referring to Figure 2, the spacer 16 has a body portion 50 with a pair of intermediate rails 52 and 54 extending upwardly therefrom on opposite sides of the longitudinal axis of the spacer and a pair of downwardly extending rails 56 and 58 with the rails 52 and 54 being aligned with rails 56 and 58. A top channel or recess 60 is formed between the rails 52 and 54 and a bottom channel or recess 62 is formed between the rails 56 and 58. The spacer 16 is arranged to be positioned between the end walls 36 of adjacent glass blocks 14 with the raised portions 38 in the walls 36 extending downwardly into the respective channels 60 and 62. The channels 60 and 62 thus position the spacer member 16 relative to the glass block walls 36 by the glass block raised portions 38 extending into the respective channels and align the adjacent blocks relative to each other. The spacer 16 has longitudinal edge portions 66 and 68 which have a rail-like configuration in section with a pair of upper and lower longitudinally extending ribs 70, 72, 74 and 76 respectively. The ribs 70-76 are arranged to abut the inclined surface 40 of the glass block walls 36 to provide further stability to the glass blocks as they are positioned in the wall 10. The ribs 70-76 are arranged to provide additional stability to that provided by the enlarged edge portions 66 and 68 of the spacer 16. The edge portions 66 and 68 have upper shoulder portions 78 and 80 and lower shoulder portions 82 and 84. The shoulder portions 78-84 all have flat surfaces 86 which are arranged to abut the adjacent wall of the glass block so that the glass block rests on the flat surfaces 86 to support and stabilize the glass blocks 14 when positioned in the wall 10. The ribs 70-76 spaced inwardly from the shoulders 78-84 are arranged to provide additional stability to the glass blocks 14 and in certain types of installations the intermediate ribs 70-76 may be omitted where the shoulders 78-84 provide adequate stability for the glass blocks 14 in the wall 10. The vertical dimension between the flat surfaces 86 of shoulders 78 and 82 and 80 and 84 is preferably such that the spacing between the curved edges 42 of the glass block is approximately 1/8″ and the width of the space is such that a space is provided between the edges of the glass block and the edges 66 and 68 of the spacer is about 1/8″. With this arrangement there is a generally rectangular space 88 between the glass block curved edges 42 and the edges 66 and 68 of spacer 16 that has dimensions of about 1/8″ by 1/8″. Such a spacing provides a space for the silicone caulking 18 which will cure and set and rigidify to further add rigidity to the glass block wall. Silicone caulking in large amounts does not rigidify throughout and thus does not provide a rigid filler material. With the dimensions of the space 88 provided between the glass block edges 42 and the spacer edges 66 and 68, the silicone caulking 18 will rigidify and provide additional stability to the glass block wall 10. The glass block wall 10 is erected as illustrated in the preferred embodiment. The frame 10 is secured to an adjacent rigid structure by means of screws or the like extending through the apertures 26 into the adjacent structure. As illustrated in Figure 1, the first course 90 of glass blocks 14 is positioned in the frame by wedging the glass blocks between the frame flanges 22 and 24. A segment of the spacer 16 referred to as the vertical spacer 46 is positioned between the vertical end walls 36 of the adjacent glass blocks so that the first course 90 includes the glass blocks 14 with the vertical spacers 46 therebetween. The end walls 36 of the glass blocks abut the vertical spacer 46 as previously described with the recessed portions 38 of each glass block extending into the adjacent channels 60 and 62 of the spacer 16 as illustrated in Figure 3. After the first course of blocks are positioned in the frame 10, as above described, a roll 44 of spacer material is positioned in abutting relation with the upper horizontal end walls 36 of the glass blocks 14 and extend the length of the first course. As previously described, the vertical spacers 46 are of such a length that they are in juxtaposition with the underside of the horizontal spacer 48. After the horizontal spacer 48 is positioned as illustrated in Figure 2 on top of the first course of blocks 90, a first glass block of the second course 92 is secured in the vertical frame 12 and a vertical spacer 46 is positioned along the glass block exposed vertical end wall 36. Then a second glass block is positioned in overlying relation with the second glass block in the first course and is moved into abutting relation with the vertical spacer 46 between the first and second glass block. This procedure is continued alternating glass blocks 14 and vertical spacers 46 until the second course 92 is completed. Thereafter a horizontal spacer 48 is positioned on the upper surface of the second course of glass blocks by again unrolling the spacer from the spacer roll so that it extends along the entire length of the wall. The end of the continuous horizontal spacer 48 is formed by cutting the spacer from the roll 44 at the preselected length. It should be understood that the horizontal spacer 48 may be cut into any suitable lengths from the roll 44 before the wall is formed as long as the horizontal spacer extends along the length of a glass block. The second course 92 has the glass blocks 14 in abutting relation with the upper surface of the horizontal spacer 48 and vertical spacers 46 are positioned between the adjacent glass blocks. The third course 94 is installed in a similar manner as are the remaining courses in the glass block wall 10. The first course 90 preferably has both end blocks 13 positioned in a vertical frame member 28 and the top course has the glass blocks positioned in an upper horizontal frame (not shown) 30. It should be understood that a unitary rectangular wall structure may be formed or preassembled with the respective vertical and horizontal frames 28 and 30 secured in position and the preassembled wall transported to a location for assembly as either a separate wall or installed in an existing opening. After the wall structure is formed, a suitable silicone caulking compound 18 is applied in the opening 88 and may be trimmed by a suitable trimming tool to form a smooth surface which will rigidify and provide aesthetic appearance in addition to rigidifying the glass block wall. Although the preferred embodiment discloses a wall formed from hollow glass blocks, it should be understood, it is within the scope of this invention to use blocks made from other materials such as plastic, for example an acrylic plastic and other suitable materials. It is also within the scope of the invention to use solid blocks or hollow blocks containing filler materials.

Claims: A glass block wall comprising a plurality of glass blocks (14) mounted in a frame (12), said glass blocks (14) each formed from a pair of hollow glass block halves with rectangular edge portions fused to each other and forming a raised continuous bead (38) therebetween, said glass blocks (14) having a generally rectangular configuration with end walls (36) and side walls (32, 34) forming edge portions (42) therebetween, said glass blocks (14) having a preselected thickness between said side walls (32, 34), said raised continuous bead (38) formed in said vertical and horizontal end walls (36) intermediate said edge portions (42), said glass blocks (14) being positioned in abutting relationship with each other with spacer members (16) positioned between adjacent end walls (36) of said glass blocks (14), said spacer member (16) having a body portion (50) with longitudinal side edge portions (66, 68) and a transverse dimension substantially equal to the distance between the block edge portions (42) of opposite side walls (32, 34) and smaller than said preselected thickness of said glass block (14) in order to provide a channel shaped recess portion (88) between adjacent block edge portions (42) and the side edge portions (66, 68), each said side edge portion (66, 68) forming a rib projecting above and below said body portion, the rib having an upper shoulder portion (78, 80) and a lower shoulder portion (82, 84) provided with flat surfaces (86) abutting the edge portions (42), characterised in that said spacer member (16) is provided with a pair of spaced intermediate rib portions (52, 54, 56, 58) forming an upper recessed portion (60) and a lower recessed portion (62) extending longitudinally on said spacer member (16) for respectively receiving a said raised bead (38) of adjacent glass blocks (14) thereby to align and stabilise adjacent glass blocks (14) of the glass block wall. A glass block wall as claimed in claim 1 wherein a filler material (18) occupies said recessed portions (88) to secure the blocks (14) to each other and said edge portions (66, 68) of the spacer members (16). A glass block wall as claimed in any preceding claim wherein said side walls (36) of the glass blocks (14) have inclined surface portions (40), said spacer member (16) having a pair of second intermediate ribs (70, 72, 74, 76) between said longitudinal edge portion (66, 68) and said first intermediate rib portions (52, 54, 56, 58), said second intermediate ribs (70, 72, 74, 76) being in abutment with said inclined surface portions (40) to further stabilise said glass blocks (14) in said wall (10). A glass block wall as claimed in any preceding claim wherein those spacer members (16) positioned between said vertical walls (36) of said glass blocks (14) have a dimension substantially equal to the height of said glass blocks (14), and those spacer members positioned between said horizontal walls of said glass blocks have a dimension greater then the length of said glass blocks (14) and extending over a plurality of glass blocks (14), said spacer members (16) positioned between said vertical walls (36) being in juxtaposition with said adjacent spacer members (16) positioned between said horizontal walls (36). A glass block wall as claimed in claim 1 wherein the frame member (12) includes two frame members (28, 30) held at an angle therebetween, said frame members (28, 30) having a body portion (20) and a pair of spaced longitudinal flanged edge portions (22, 24) extending angularly therefrom, and which converge towards each other to form a channel with the body portion (20) having an entrance dimension slightly less than said preselected thickness of said blocks (14) to receive the blocks (14) therein in frictional engagement, certain of said blocks (14) being arranged to have said side walls (32, 34) in frictional engagement with the flanged edge portions (22, 24) of one of said frame members (28) and the others of said blocks (14) being arranged to have said side walls (32, 34) in frictional engagement with the other frame member (30) of said frame (12). A spacer member for positioning between adjacent blocks of a glass block wall, each glass block having a beaded portion formed between two fused halves thereof, the spacer member comprising, an elongated body portion (50) formed from a flexible plastics material having sufficient strength to resist deformation under load, said body portion (50) having a top surface, a bottom surface and side edge portions (66, 68) forming a rib projecting above and below said body portion, the rib having an upper shoulder portion (78, 80) and a lower shoulder portion (82, 84) provided with flat surfaces (86) for abutting outer edge portions (42) of adjacent blocks, the spacer member having a width corresponding substantially to the distance between the opposite outer edge portions (42) of the block, characterised in that said top surface of the body portion (50) has a pair of spaced parallel longitudinal ribs (52, 54) intermediate the respective ends of the spacer member and forming a recess portion (60) therebetween for receiving the bead of a glass block, formed by fusion of glass block halves to form the glass block, mounted on the spacer member, said bottom surface having a second pair of spaced parallel longitudinal ribs (56, 58) in aligned relation with said first pair of ribs (52, 54) and forming a lower recess portion (56, 52) for receiving the said bead of the glass block adjacent thereto, thereby to align and stabilise adjacent glass blocks in the glass block wall. A method of fabricating a glass block wall comprising, (a) positioning a first glass block (14) in a corner (31) of a frame (12) in frictional engagement with frame members (28, 30) thereof disposed in angular relationship, (b) forming a first course of glass blocks (14) along one frame member (28) thereof in frictional engagement therewith, (c) positioning a spacer member (16) according to any one of claims 7 or 8 between adjacent end walls of the glass blocks (14) along said first course, each spacer member (16) having lengths substantially equal to the height of said glass blocks (14), (d) positioning a said spacer member (16) having a width less than that of the glass blocks (14) over the top walls of said glass blocks (14) in said first course to be in substantial juxtaposition with the spacer member (16) between said end walls of the blocks (14), (e) forming a second course of glass blocks (14) along the spacer member (16) over the first course so as to form recesses (88) between facing glass block edges along the respective courses and the edges (66, 68) of the spacer member (16), the first glass block (14) in the second course being in frictional engagement with the frame member (28), (f) positioning a spacer member (16) between the adjacent end walls of the glass blocks (14) in the second course and repeating steps (d) through (f) to form additional glass block courses with spacer members (16) therebetween and between adjacent walls of the glass blocks (14) in each course until the wall is complete. A method of fabricating a glass block wall as claimed in claim 7 wherein a filler material (18) is disposed in the recesses (88) further to stabilise the glass block wall (10).

Inventors: MCMARLIN ROBERT M, MCMARLIN, ROBERT M.
Applicants: PITTSBURGH CORNING CORP, PITTSBURGH CORNING CORPORATION
Application year: 1991
Main classification: E04C1
IPC codes: E04B2, E04C1