BLOCK SYSTEM

Abstract: A construction block (2) is disclosed along with a method of producing and assembling a plurality of the construction blocks where the blocks have internal cages (3) around a central passage (71), said central passage opening to top (1), bottom (4) or side (5) openings in the blocks, and from which cage (3) support rods (6, 7) extend to hook chain lifts to the blocks (2) and to guide bottom openings (4) of top blocks into predetermined alignment wih the top opening (1) of the bottom blocks. The casting technique allows not only for the novel lifting and alignment construction of the blocks, but also allows for novel external and internal features to be incorporated into the blocks, such as studs, mounting bolts (64) for interior walls and bricks or brick facades for the exterior walls of the blocks.

Description: BLOCK SYSTEM PRIORITY: Priority is claimed on PROVISIONAL PATENT no: 60/078,992 filed 3/23/98 by Ted Dial. KNOWN PRIOR ART: The prior art shows embedded lifting mechanisms. The prior art also shows building members and concrete building members having hollow interiors. The prior art also shows building members assembled to receive a concrete matrix. GENERAL DISCUSSION OF THE INVENTION The invention is a specialized building block and a building process using the specialized blocks for constructing walls, building exteriors and decorative architectural detail such as cornices, eaves, window and door casings and lintels built independently and in conjunction with walls a process for constructing the blocks is also taught. The invention uses blocks which, when assembled, have a series of intersecting chambers which allow for a continuous concrete pour throughout the structure in order to secure the blocks together. The blocks are defined by specialized exterior features, by the channel system, by the cage and opening layout for lifting and centering one block on top of another. In this way a very strong structure is made where certain architectural details become part of the structure as opposed to merely being mounted onto the structure or attached to the structure. No attachment devices or fasteners are needed as are found in other known practices of constructing architectural details such as eaves, cornices and the like. Incorporation of these features into poured block structures which are integral parts of the exterior walls saves time and labor costs. In the preferred embodiment, the products are pre-fabricated and stacked for shipping and construction. No exterior finishes are required to be added during construction because all desired finishes and desired shapes, both decorative and functional, are already part of this structural product. The structural integrity of the building (framing, etc), the interior finish surfaces, the weather controlling aspect, and the complete decorative aspect are all one and the same in this product. It is therefore an object of the invention to provide an easily constructed and moved building member. Another object of the invention is to provide a block which can easily be lifted in place by at least one lifting rod and thereafter stacked and filled with concrete or other matrix without the rod interfering with the concrete pour. It is a further object of the invention to provide for a process for using the modified blocks in order to construct structures with desired architectural detail with minimal labor. These and other objects and advantages of the invention will become better understood hereinafter from a consideration of the specification with reference to the accompanying drawings forming part thereof, and in which like numerals correspond to parts throughout the several views of the invention. BRIEF DESCRIPTION OF THE DRAWINGS For a further understanding of the nature and objects of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which like parts are given like reference numerals and wherein: Figure 1 is a plan view of one of the blocks described by the invention. Figure 2(a) is a plan view of a plug having a notched centering means and a cage mounted on the centering means with a single lifting rod. Figure 2(b) is a plan view of a jig having a notched centering means and raised guides for building properly centered cages. Figure 3 is a plan view of a cage having lifting rods. Figure 4 is a cut away view of a structural wall detail, here a window frame, of the type shown in Figure 5 through the 4-4 axis of Figure 5. Figure 4a is a cross section of the detail shown in Figure 4 through the 4a-4a axis. Figure 4b is a cross section of Figure 4a through the 4b-4b axis. Figure 5 is a window frame incorporating the structure described herein. Figure 6 is an exploded view of a mold used for making blocks. Figure 7 is a cross sectional view of a wall in a two story structure using the technology described herein. Figure 8 shows an assembled mold with a modified cage. Figure 9 shows a press and pull mechanism for removing plugs from set pours in the mold. Figure 10 shows a plan view of the structure described in Figure 7. Figure 11 shows an architectural detail of a window, such as is shown in Figure 5, during the assembly process. Figure 12 shows a lintel block used in the construction of the window shown in Figure 1 1. Figure 13 shows a wall being assembled using the blocks described herein. Figure 14 shows the wall of Figure 13 with a cornice and top plate. Figure 15 shows an interior view of a mold wall detail. Figure 16 shows a cross section of the wall detail of Figure 15 through the 16-16 axis. Figure 17 shows an interior view of an alternative mold wall detail. Figure 18a shows a cross section of the mold wall detail of Figure 17 through the 18a- 18a axis using short studs as an attachment means. Figure 18b shows a cross section of the mold wall detail of Figure 17 through the 18b- 18b axis using a long stud as an attachment means Figure 19 shows a block wall produced using a mold detail such as that shown in Figure 15. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT As can best be seen by Figure 1, one invention comprises a specialized block having a special purpose for construction of a building. The blocks, can be understood by reference to Figure 1 which shows a perspective view of a block utilizing the construction techniques set out herein. This block comprises a block top opening 1 and at least one block additional opening, here a bottom opening 4 and a side opening 5. At least a portion of the internal area of the block is hollow in order to provide a passage which allows the block top open 1 to communicate with the block bottom opening 4 or side opening 5 or both. . The architectural block, as shown in Figures 1 and 3 comprises at least one cage(3)having a first side frame member(3f)within the first side(2a)of the block and a second side frame member(3g)within the second side(2b)of the block and wherein the cage(4)further comprises an attachment rod(3e)connecting the first side frame member(3f)to the second side frame member(3g)and wherein the at least one first guide rod(6)has a left side(6a)and a right side(6b)and wherein the left side(6a)of the first guide rod(6)is attached to the first side frame member(3f)and the right side(6b)is attached to the second side frame member(3g). The block has a top(2e)and a bottom(2f), and further comprises a first side(2a), a second side(2b), a third side(2c) and a fourth side(2d) and said sides, top and bottom defining an enclosure which enclosure defines at least one first block opening(l)which is continuous with a passage through the block which passage may be continuous with at least one second block 1 opening(4)in the second block if the second block is placed against the architectural block, 2 said architectural block further comprising; 3 In the preferred embodiment the bottom opening 4 is larger than the top opening 1. 4 The bottom opening 4 is large enough to receive first and second guiding rods 6 and 7 5 respectively. The guide rods 6 may come up from the center of the top opening or from the 6 walls on either side of the top opening 1. The guide rods 6 are preferably curved at the top 7 so that as a top block is lowered by its own guide rods 6 and 7 onto a lower block the bottom 8 opening 4 of the top block accepts the guide rods 6 and 7 of the bottom block into the bottom 9 opening 4 and the bottom edges 14 of the bottom opening 4 are guided by the guide rod 6 into 10 the appropriate location. As a result, while only one guide rod is needed, at least a first guide 11 6 and a second guide 7 are present in the preferred embodiment for proper centering of a top 12 block with a bottom block as shown in Figure 13. 13 In the preferred embodiment, the bottom opening 4 is larger than the top opening 1 so 14 that the guide rods will appropriately guide the bottom opening in place over a lower brick 15 and also to make the concrete pours more even by preventing concrete build up within the 16 pour. In addition. The edges 14 of the bottom opening 4 may be notched so that these notches 17 14(a) could be guided over the rods 6 and 7. 18 The spacing and use of the guide rods 6 and 7 defines how many are needed and what 19 shapes are possible. The size of the rods is governed by the strength requirements since the 20 rods serve a lifting purpose and a guiding purpose. In addition, the rods act as reinforcing 21 rods when concrete is poured into the assembled blocks. The second guide rod 7 is shown 22 here as being parallel to the first guide rod 6. However, it can easily be seen that it may be at 23 an angle off parallel all the way to being perpendicular to form a dome for guiding a second 24 block onto a first block. 25 In the preferred embodiment there are two rods for easy lifting and the rods travel from 26 the left side 9 of the top opening 1 to the right side 10 of the top opening 1. Once one block 27 is on top in line with another lower block (as shown in Figure 13) concrete may be poured 28 through the top block top opening 1 and then it travels through to other blocks which have 29 openings aligned with this top block. Guide rods may extend from the side openings for a 30 similar purpose although this is not necessary in the preferred embodiment given the function 31 of the rods to allow for easy lifting and placement of the blocks. 32 As shown in Figure 1 and 2(A), when two guide rods are used, they can come off the cage at different locations. One or more rods may be used. If one rod 6 were used, it would be preferably centered based on the weight of the block 2. Tabs or spacers 15 are attached to the cage, here at the bottom frame 37. The bottom legs of the cage extend past the bottom frame 37 to support the cage off the base 19 of the plug 1 1 as shown in Figure 6. As can be seen by reference to Figure 2(A) the edges of the plug 1 1 are curved. In Figure 2(A), when the cage is in place on the plug a portion of the guide rods lays on the notches 12 of the plug so that the cage is properly aligned. The cage side may have an upper and lower part running along the side of the plug. As shown in Figure 2(B), the internal cage 3 may be built on a jig which has top notches 73 and bottom notches 74 to receive the top frame 36 and bottom frame 37 respectively. Since the rods 6 and 7 must extend over the top, raised guides 75 may be used to assure the proper height of the guide rods 6 and 7. The raised guides 75 may define raised notches 76 which receive the guide rods 6 and 7 as they are run from one side of the cage over the raised guides 75 to the other side of the cage. To further guide the placement of the rods 6 and 7, right side notches 77 and 78 and left side notches 79 and 80 are provided. Rod 6 is attached from the top frame 36, fit through right notch 78, into the nearer guide 75 within the notch 76, through the left notch 80 and back onto the far side of the top frame 36. This same design arrangement is provided for the other rod 7. To provide proper placement of the tabs or spacers 15, short side spacer alignment 81 and long side spacer alignment 82 may be used to show where the spacer is to be inserted and to set the distance if the spacer 15 extends inward from the cage. Figure 3 shows the use of two rods 6 and 7. In order to allow the blocks to be lifted by the guide rods 6 and 7 an internal cage 3 is built within the block itself. Cross rods (not shown) may extend through the center of the block between sides of the internal cage 4 in order to add additional re-enforcing strength to the concrete poured within the blocks although this is typically unnecessary. The use of spacers 15 as shown in Figure 3 throughout the cage 3 allows the cage to be centered on plug 11 even without notches 12. As shown in Figure 3 the cage 3 is preferably comprised of a bottom frame 37, a side frame 38 and a top frame 36 formed of interlocking metal bars of sufficient thickness to support the blocks when lifted by support bars 6 and 7 when the block is lifted. While the support rods 6 and 7 are shown at either side, of the cage, their number and location is 1 discretionary as long as they serve their guiding function, their re-enforcing function, and their 2 lifting function. 3 The internal cage not only allows for the lifting and strengthening the position of the 4 guide rods but also adds structural strength to the concrete block 1. The cage may be partially 5 or completely encased in concrete although at least a portion of it is preferably encased in 6 concrete so that the block may be lifted by the rods 6 and 7 extending from the cage 4. 7 In the pouring process the cage may be suspended within the mold for the block. As 8 shown in Figure 2, the guide rod 6 may be centered on a notch 12 on a plug 11 to properly 9 center the cage and this may also be done with spacers 15. Once in place and centered, 10 concrete is poured into a mold as described in more detail below. 11 Figure 6 shows the mold assembly. During assembly, a cage as shown in Figure 2a 12 or 3 is put in place before side plugs are installed. Figure 6 shows the assembly of a mold for 13 manufacturing blocks with bottom and side openings. The mold consists of a bottom plug 11 14 which is fitted within an opening in the base 19 of the mold. This bottom plug 11 will form 15 the top opening 1 and bottom opening 4 if it fits all the way through the block. If only a top 16 or bottom opening is desired, the plug will not pass all the way through. The cage 3 also 17 shown in Figure 3 is then put on top of this plug 11 and the side walls 17 and 17a are attached 18 so that either of the side plugs 16 or 16a would touch the bottom plug 11, if it is desired to 19 have either of the side openings 5 in the block. As is obvious, if there is only one side plug 20 16 or 16a there will be only one side opening. If there are no side plugs, there will be no side 21 openings. If a side plug does not reach the bottom plug 11 , there would be an indention, but 22 no passage through the block. 23 If there is no bottom plug 11 , but the left side plug 16a and right side plug 16 touch, 24 there will be side openings, but no bottom opening. If a top plug is inserted into this 25 arrangement, there would be a top opening and side opening, but no bottom opening. 26 Likewise, if the bottom plug 11 does not reach the top of the mold, there will be a bottom 27 opening, but no top opening. Specialized blocks for corners, bottoms and tops may thereby 28 be formed. 29 In the preferred embodiment, both the bottom plug 11 and side plugs 16 are tapered 30 from the base 19 or wall 17, respectively, to a more narrow end to make removal easier. 31 Since the bottom plug 11 is tapered from a wide base to a narrow top, the top face 16b of the 32 side plug 16a is tapered so as to fit against the side face 1 la of the bottom plug 11. This fit 1 leaves little or no concrete between the faces 16a and 1 la or leaves a thin enough sheet of 2 concrete so that it may be easily punched out. Assembly bars 26 are inserted through the base 3 19 below the bottom of the plug 11 to hold the plug 1 1 in place during the pour. These rods 4 26 will later be removed to allow the plug to be removed. 5 Ridges 23, shown in Figure 6, along the side of the plug 11 result in notches 14a along 6 the bottom edges 14 of the bottom opening 4 of the poured block 2 as shown in Figure 1. 7 As can best be seen by reference to Figure 8, c-clamps 28 attached to posts 29 on each 8 of the two separate side walls 17 and 17a of the mold serve to hold the side walls together 9 relative to one another as the mold is poured. The base 19 is also held to the side walls 17 and 10 17a by way of clamps 39. 11 When the mold is assembled, as shown in Figure 8, the concrete may be poured into 12 the mold. If desired, the top may be troweled smooth, exposing a portion of the plug top or 13 having a thin enough layer over the plug top that it may be punched out. Figure 8 shows the 14 internal cage out of the assembled mold, but as discussed above, referring to Figure 6, 15 typically the cage would be put in before any side plugs 16. Here, in Figure 8, the bottom of 16 the cage 3 is open on the side. The side legs 83 can fit on either side of the side wall plugs 17 16 and 16(a) shown in Figure 8. 18 It can be seen that if the side plugs 16 were to meet in the center without a bottom plug 19 11. the cage 3 could fit over the side plugs 16. This would form a lifting rod over block which 20 had a passage which was below but not affected by the lifting rods. The lifting rods would 21 still serve their lifting function. They would also serve their reinforcing function if a second 22 block with a bottom opening were placed over the lifting rods. 23 After the plugs, walls and cage are assembled, concrete can be poured and the entire 24 mold allowed to cure, fully or partially, at which point the plugs are pulled, pressed or 25 knocked out and the block is ready to use. 26 The ridges 23 which may rise from the bottom plug 1 1 to provide guides in the 27 finished block which receive the support bars 6 and 7 shown in Figure 3 when one block is 28 placed atop another may be of a variety of shapes without departing from the concept 29 embodied herein. 30 After an appropriate amount of drying, the plugs 11 are then drawn out or pressed out 31 or knocked out of the center of the block. The plugs 11 may have notches 12 which allow for 32 them to assist in the alignment of the cage 9. The edges 13 are rounded and the size of the 1 block is tapered in order to assist with the plug's removal. This tapering also leads to the 2 larger size of the bottom of the block versus the top block opening 1. 3 As can best be seen by reference to Figure 9, after a block is produced within the mold, 4 the plug 1 1 may be removed by jacking the plug 1 1 out or by pulling the plug out from the 5 bottom or a combination of the two techniques. This may be done while the concrete is fully 6 hardened or during the drying process when the mold is sufficiently set in order to allow the 7 passages defined by the plugs to remain in place. There may be small holes in the plugs 8 which receive pins to test the concrete for drying. In Figure 9 it can be seen that brace 9 supports 40 support a brace 41 against the sides of the mold. The brace 41 is also supported 10 against the jack arm 44 by chains 42 hooked into the guiding rods 6 and 7 of the block. A 11 jack is inserted between the plug 11 and the brace 41 and as the jack arm 44 pushes against 12 the brace 41, the jack base 45 pushes the plug 11 out. 13 Figure 9 also shows the use of a eye-bolt 46 built into the bottom of the plug 11. This 14 eye-bolt 46 may be attached to a hook 48 on a beam 47. This arrangement is held off the floor 15 by placing the mold on I-beams 49 and the beam 47 is pressed to the floor, pulling the plug 16 1 1 from the mold. These same technologies may be used on the side plugs which are smaller 17 and require less stress to remove. 18 Figure 4 shows the use of traditional framing on offsets created by the construction 19 techniques utilized herein. Here, 8 inch wide [.203 m] frame blocks 31 extend around the 0 window 50. As seen looking down in cross section, 4-4, shown in Figure 4, the 8 inch [.203 1 m] frame blocks 31 are offset to stick out from the 16 inch [.406 m] structural blocks 21 by 2 a predetermined distance 31(c). The front face 31(a) of the blocks facing outward may be 3 slightly less far out than the cast sill 51 on which the 8 inch [.203 m] frame blocks 31 and 4 window 50 rest. The actual window 50 is recessed from the front face 31(a) of the 8 inch 25 [.203 m] frame blocks 31. In this embodiment, the interior walls 52 are mounted on studs 53 26 in the manner well known in the art. The window is recessed within the walls by a window 27 casing 54 of the type also known in the art. By way of example, the 8 inch [.203 m] frame 28 blocks 31 abut the 16 inch [.406 m] structural blocks 21 which are here thirty inches [.762 m] 29 long and the frame blocks 31 may be indented within the 8 inch difference [.203 m]. The side 30 openings of the frame blocks 31 and structural blocks 21 would preferably be aligned as 31 shown in Figure 4 even though the blocks themselves are of different widths. 32 As shown in Figure 5, a solid cast cornice or lintel 55 may be placed atop the window frame described by the 8 inch [.203 m] frame blocks 31. This cornice 40 would be supported by and integral with the 8 inch [.203 m] frame blocks. Figure 4(a) shows a side section of the cross section shown in Figure 4. Several benefits of the blocks described above are apparent from this figure. Referring to the top block, lintel 55 of the window treatment which is shown in this Figure 4(a), it can be seen that structural and design details may be incorporated into a poured block. The structural detail here is a plate 25 which receives a beam 24 atop a wooden wall stud 53 which rests on the plate 25. The plate is a part of the poured block. In addition, this lintel block 55 incorporates a design exterior treatment 72. While both the plate 25 and exterior treatment 72 are shown here in a single block, it is obvious that either detail may be incorporated into a block without the other. Architectural details are shown in Figures 4, 5 and 10 for an exterior window 50. The casing for the window 50 is built onto special blocks set as shown in Figure 11 among the remaining framework. Figure 1 1 shows how the window treatment described in Figures 4 and 5 would be assembled with a lintel 55 which, here, has neither a special exterior treatment nor a plate. Here, the 8-inch [.203 m] frame blocks 31 are in place and the lintel 55 is being lowered by way of the support rods 6 and 7. A side opening 56 in the lintel may allow concrete to connect the lintel 55 to the 16 inch blocks on either side which would have cooperating openings. The lintel 55 may also have bottom openings (not shown) to allow concrete coming into the lintel's interior through lintel top openings 57 or side openings 56 to move into the top openings in the top most 8-inch [.203 m] frame block. From there, the concrete would pass into the lower 8-inch [.203 m] frame blocks sealing the structure together. Alternatively, after concrete has been poured into the 8-inch [.203 m] frame blocks, the lintel 55 may be placed on top. As the lintel 55 shows in Figure 12 and 11 , there may be multiple top openings 57 to allow pours down the left and right 8-inch [.203 m] frame blocks 31. Similarly, there would be corresponding multiple bottom openings 4 (not shown) to allow the concrete to flow through to top openings in the 8-inch [.203 m] frame blocks 31 below the top openings 57. Figure 12 shows a detailed view of the lintel 55 shown in Figure 11. Figure 7 shows a side cross section of a house where a series of blocks as shown in Figure 1 are stacked one on top of the other and as can be seen here 12-inch [.305 m] small blocks 20 may have holes bottom holes in alignment, not only with each other, but also with 16-inch [.406 m] structural blocks 21 by virtue of having the location of the plug off center during their formation in order to allow for the placement of a joist 24 on a plate 25 atop the 16-inch [.406 m] structural block 21. This plate 25 is the area the larger 16-inch [.406 m] structural blocks 21 which is not covered by the smaller 12-inch [.305 m] small blocks 20. This is compared with the formed plate 25 which is an integral part of the top block 55 shown in Figure 4(a). A similar arrangement as present where 16-inch [.406 m] structural blocks 21 are aligned with 18-inch [.457 m] middle blocks 22 to allow for two by four wall lumber 27 to be run off of a sixteen inch [.406 m] I- Joist 26 which in turn rests on a plate 28 which is the uncovered axea of the 22-inch [.559 m] bottom block 23 when the 18-inch [.457 m] middle block 22 is placed on the larger block as shown in Figure 7. Similar to the offset of the 12- inch [.305 m] small blocks, the 16-inch [.406 m] structural blocks and 18-inch[.457 m] middle blocks 22 may have bottom openings 4 which are offset so as to be aligned with the top openings on 22-inch [.559 m] bottom blocks 23 and may define an offset 28 on which to place a joist 26 to support the construction within the walls so described. The purpose being to incorporate the architectural details into the blocks, rather than to attach these details at a latter point in time. Figure 7 also shows how the blocks may be built directly off of the foundation 96 or how a intermediary foundation block 95 may be placed on the foundation 96 which in turn supports seals 94. Figure 13 shows several blocks being stacked together utilizing the method taught hereunder, utilizing a crane (not shown) to lower blocks via a hook 84 and chain 85 attached to a small spacing beam 86 which is attached by two second hooks 87 and support chains 88 attached to the block support rods 6 and 7. It can be seen that the blocks may be offset to provide a more interwoven structural cross section. Figure 14 shows the wall of Figure 13 with a top plate where several of the lifting bars 6 and 7 have been removed. Figure 14 shows the top treatment for a row of blocks, such as that shown in Figure 13. In this case, a group of cornice blocks 93, of similar construction, but having built in architectural details (a decorative overhang here) is placed atop the row of twelve inch blocks 20. Concrete may be poured through the openings in this top after the 10 1 cornice support rods 6 and 7 are cut from the top of the cornice blocks. In this way, a flat 2 surface is presented. Bolts may be set in the concrete pour and a top plate 89, of wood or 3 metal, may be bolted to these bolts to allow for greater ease of building off of the cornice 4 blocks 93. 5 The interior walls of the molds may be modified in order to provide enhanced 6 architectural detail or to provide for anchor bolts for interior finishes. As can best be seen by 7 reference to Figures 15 and 16, the interior surface 60 of the outside mold wall 66 defines 8 block openings 62. These block openings 62 may receive brick facing 64 or may be left 9 empty to give texture to the block exterior face 68, shown in Figure 19. The interior surface 10 60 faces the outside surface of the exterior face 68 of a block 69 to be made within the mold. 11 The end product is a block such as that shown in Figure 19. Hence, a finish may be applied 12 to the exterior blocks by virtue of embedding a finishing material through this method or by 13 imparting a finished texture. While a brick texture is shown here, any number of different 14 textures could be encompassed by this technique including a vinyl or wood type finish which 15 may be painted to look more like the final finished product. The key being to either (a) embed 16 the finish material within the block by putting it in the mold or (b) texture the exterior of the 17 wall by having the finish on the interior wall of the mold. The finishing means is either an 18 exterior texture or a plurality of finish pieces (here brick or wood studs) where the finish 19 pieces have an exposed side and an embedded side where the embedded side is within the 20 block itself so that the finish pieces are partially embedded within the block and partially 21 exposed from the block. 22 As shown in Figure 19, there may be a continuous wall formed with this brick pattern, 23 joined, as shown here, by intermediary blocks 90 and cornered by a comer block 91. Gaps 24 92 have been left in this embodiment by the mold into which these intermediary blocks 90 25 may be fit. 26 This same technique may be used, as shown in Figures 17 and 18a and 18b for 27 attaching mounting studs 65. Mounting studs as used herein refers to wooden studs, wooden 28 pegs, embedded nails or even bolts 65a, as shown in Figure 4 within the concrete matrix for 29 mounting a finish to the exterior or interior surfaces of the finished blocks. These mounting 30 studs 65 are inserted within openings 63 at predetermined points on the interior surface 61 of 31 the inner mold wall 67. The inner face 61 of the interior mold wall 67 corresponds to the 32 interior face 70 of the block 2. It is the part of block 2 which faces the interior of the building 11

Claims: 1 and where studs are attached. As shown in Figure 18(a), full length studs may be used which 2 could be aligned with studs in the block below. As shown in Figure 18(b) the studs 65 or bolts 3 65(a) as shown in Figure 4 may be much smaller and less obtrusive. The bolds 65(a) may be 4 nails and may be set against a plate of wood or metal to cushion a blow which would be 5 received when the interior wall is attached. It is also taught that the exterior treatment may 6 be attached to similarly placed studs on this exterior surface were that desirable merely by 7 having an exterior mold wall which was constructed in the manner taught hereunder for 8 interior mold walls. 9 Since the arrangement, depth, shape and number of the openings 63 may be varied in 10 an infinite variety, an infinite variety of finishes may be given to the exterior of the concrete 11 where studs or bricks are not placed within these openings 63 or where different finishing 12 materials are placed within these openings 63. 13 As shown in Figure 4, the wide portion of the retaining bolt 65 a which is embedded 14 within the concrete when the block is poured may be wider than the exposed end. This is also 15 true if mounting studs 65 are used. While here the mounting studs 65 are round, they may be 16 of any shape and may extend any length along the blocks. In this way, the mounting blocks 17 65 may extend down the block and join with the next lower blocks mounting studs to form 18 a continuous stud for mounting interior or exterior wall treatments (sheet rock, brick, etc.). 19 An example of this is shown in Figure 4 where a wooden stud is attached by way of a bolt into 0 the brick. If the stud was instead incorporated into the poured mold, the same effect would 21 be realized. 22 During the concrete mixing stage, the concrete or the concrete which makes the facade 3 may be mixed with a concrete dye to give it the appearance of stone or to enhance its 24 appearance as brick. Hence architectural details may be a brick facade designed into the mold 25 or it may be a cornice 93 or window treatment 72 such as is shown in Figure 14 and Figure 26 4(a), respectively. Because many varying and different embodiments may be made within 27 the scope of the inventive concept herein taught and because many modifications may be 28 made in the embodiment(s) herein detailed in accordance with the descriptive requirements 29 of the law, it is to be understood that the details herein are to be interpreted as illustrative and 30 not in a limiting sense. 31 CLAIMS: 32 33 1. An architectural block(2)for use with at least one second block having a second block 12 opening(4)comprising; (A) a top(2e)and a bottom(2f), and further comprising a first side(2a), a second side(2b), a third side(2c) and a fourth side(2d) and said sides, top and bottom defining an enclosure which enclosure defines at least one first block opening(l)which is continuous with a passage through the block which passage may be continuous with at least one second block opening(4)in the second block if the second block is placed against the architectural block, said architectural block further comprising; (B) at least one first guide rod(6)extending from within the first side to within the second side and across the at least one first block opening(l). 2. The architectural block of claim 1 wherein the at least one first guide rod(6) is further described as extending above the top of the block. 3. The architectural block of claim 2 wherein the at least one first guide rod(6)has a length between the first side and the second side and where the at least one first block opening is located at the block top. 4. The architectural block of claim 3 wherein the at least one guide rod curves from the point where it leaves the first side to the point where it enters the second side of the block. 5. The architectural block of claim 3 wherein the at least one second block has a bottom and wherein the second block opening(4) is a bottom opening(4)in the bottom having a bottom diameter and wherein the length of the at least one guide rod(6)is less than the bottom diameter. 6. The architectural block of claim 4 wherein the second block at least one guide rod(6)is approximately the same as the bottom opening so that the bottom opening(4)is approximately centered relative to the architectural block first opening(l)if the second block is placed on the architectural block with the at least one guide rod within the bottom opening(4)of the second block. 7. The architectural block of claim 3 further comprising at least one second guide rod(7)extending from within one side of the block and across the at least one first block opening to a different side of the block. 8. The architectural block of claim 7 wherein the second guide rod(7)is further described as passing above the first block opening(l )and is approximately parallel to the at least one first guide rod. 13 1 9. The architectural block of claim 7 wherein the second guide rod(7)is further described as 2 not being parallel to the first guide rod(6)and is defined as passing above the first block 3 opening(l)and passing under the at least one first guide rod(6)to form the partial framework 4 of a dome above the architectural block. 5 10. The architectural block of claim 2 wherein the second block may describe at least one 6 groove(14)adjacent to the bottom opening(4)so that when the at least one first guide rod(6)is 7 inserted within the groove(14), second block bottom opening is aligned with the at least one 8 first opening(l)in the architectural block. 9 1 1. The architectural block of claim 1 further comprising at least one cage(3)having a first 10 side frame member(3f)within the first side(2a)of the block and a second side frame 11 member(3g)within the second side(2b)of the block and wherein the cage(4)further comprises 12 an attachment rod(3e)connecting the first side frame member(3f)to the second side frame 13 member(3g)and wherein the at least one first guide rod(6)has a left side(6a)and a right 14 side(6b)and wherein the left side(6a)of the first guide rod(6)is attached to the first side frame 15 member(3f)and the right side(6b)is attached to the second side frame member(3g). 16 12. The architectural block of claim 11 wherein the cage further comprises at least one 17 reinforcing member(3a)extending from the first side frame member(3f)into the block passage. 18 13. The architectural block of claim 1 1 wherein the cage(3)further comprises at least one 19 reinforcing member(3d)passing from the first side frame member(3f)through the third 20 side(2c)and then connecting to the second frame member(3g). 21 22 14. The block of claim 1 further comprising at least one external surface, and a finishing 23 means and where said finishing means(64)further comprises an embedded end(64a)where said 24 embedded end is within the at least one external surface of the block and where said finishing 25 means further comprises and exposed end(64b) and where said exposed end is not embedded 26 within the at least one external surface. 27 15. The block of claim 14 wherein the finishing means(64)is from the group comprised of a 28 stud(53), a bolt(65a),a nail(65a),a brick(64)and a metal plate. 29 16. The block of claim 14 wherein the finishing means comprises a plurality of finish 30 pieces(64)said pieces(64)having an exposed side(64g)and an embedded side(64a)where the 31 embedded side(64a)is within the block(l)so that the finish pieces are partially embedded 32 within the first side. 14 1 17. The block of claim 16 wherein finish pieces(64)are bricks. 2 18. The block of claim 14 wherein the at lest one external surface is not on the same side as 3 at least one second external surface and where the block second external surface further 4 comprises at least one second finishing means(64)for finishing the exterior of the block. 5 19. The block of claim 14 wherein the finishing means(64)embedded end comprises a large 6 end(64a)having an embedded width and wherein the exposed end(64b)has an exposed width 7 which exposed width is less than the embedded width. 8 20. The block of claim 1 further comprising at least one outside face, at least a portion of said 9 outside face being in the shape of an architectural detail(72). 10 21. The block of claim 1 further comprising a lip(25)facing the block top(2e)for receiving 11 cross bracing(24). 12 22. A Method of using construction blocks having at least one first side and a top above the 13 first side(2a)and a first opening(l)in the top(2e)and at least one second side(2b)opposed from 14 the first side(2a)and wherein the first opening(l)is located between the first side(2a)and 15 second side(2b)and wherein the blocks further comprise a bottom(2f), said bottom defining 16 a bottom opening(4)with at least one passage through the block from the first opening(l)to 17 the bottom opening(4)comprising the steps of: 18 (A) placing at least one reinforcing member(6)within the passage of at least one first 19 block(21)and extending out of the at least one first block top(2e)and across the at least one 20 first block first opening(l); 21 (B) stacking a second block(20)so that the at least one reinforcing member(6)extends 22 within the bottom opening(4)of the second block(20)so that the passage of the second 23 block(20)is continuous with at least a portion of the passage of at least one first block(21)to 24 form a common passage(71 ); 25 (C) pouring concrete within the common passage(71 ). 26 23. The method of claim 22 wherein the step of placing a reinforcing member(6)further 27 comprises the step of placing the reinforcing member(6)within the second side(2g)of the at 28 least one first block. 29 24. The method of claim 23 wherein the step of placing the reinforcing member further 30 comprises the step of placing a cage(3)of reinforcing material within the block(21 )and around 31 the first opening(l )and attaching the reinforcing member to the cage(3). 32 25. The method of claim 23 wherein the step of stacking further comprises the step of lifting 15 1 at least one second block(20)onto first block(21)by way of the reinforcing member(6). 2 26. The method of claim 23 wherein reinforcing member(6)further comprises at least one 3 lifting rod means(6)so that when the second block may be lifted by the lifting rod means. 4 27. The method of claim 23 wherein the reinforcing member(6)further comprises an aligning 5 means(6)to align the bottom opening(4)of the second block(20)with the top opening(l)first 6 block(20). 7 28. The method of claim 27 wherein the aligning means is a rod(6) extending upward from 8 the first block and against the side(14)of the bottom opening(4)in the second block(20)so that 9 the bottom opening(4)is aligned with at least a portion of the top opening(l)of the at least one 10 first block(21). 11 29. The method of claim 22 wherein the blocks further comprise an exterior finishing 12 means(64)for providing a finish to the exterior surface and wherein the method further 13 comprises the step of alining the finishing means(64)of adjoining blocks so as to form a line 14 of finishing means at the desired location for applying a finish. 15 30. The method of claim 29 wherein the finishing means further comprises a stud, a bolt, a 16 nail, a brick and a metal plate. 17 31. A method of constructing blocks for use in construction comprising the steps of: 18 (a) determining a flow direction from the top, bottom and sides and preparing a passage 19 diagram to determine flow through a passage(71)so that liquid may flow through the 20 passage(71)when the construction block is finished; 21 (b) preparing a mold(17)having an interior surface(16)in the shape of the exterior of the 22 outermost diameter of the block; 23 (c) placing at least one plug(l l)at the location of the passage; 24 (d) pouring concrete around cage(3)and plug(l 1); 25 (e) removing the plugs. 26 32. The method of claim 31 where the plug(l l)is tapered with a wide end and a narrow end 27 so that the wide end is exterior from the pour area. 28 33. The method of claim 32 where the wide end of the plug( 11 )abuts a wall( 19)of the block. 29 34. The method of claim 33 where the narrow end is substantially at the top of the mold(l 7). 30 35. The method of the claim 31 further comprising at least one second plug(16)having a 31 tapered end with a wide end and a narrow end and wherein the at least one second plug 32 narrow end(16b)contacts the at least one plug so that the passage is formed when the two 16 1 plugs( 1 1 , 16)are removed. 2 36. The method of claim 31 further comprising the step of building a cage(3)between the wide 3 end and the narrow end of the plug(l 1), so that when concrete is poured around the cage(3)at 4 least a portion of the cage(3)is encased in concrete. 5 37. The method of claim 36 wherein said cage(3)further comprises at least one 6 spacer(15)located between the cage and plug so that at least a portion of the cage(3)does not 7 contact the plug( 11). 8 38. The method of claim 3 wherein the plug(l l)has a left side and a right side and wherein 9 the cage(3)fits onto the left side and right side of the plug so that when concrete is poured 10 around the cage(3), the cage(3)is on either of two sides of the plug(l 1). 11 39. The method of claim 36 wherein the cage(3)further comprises at least one guide 12 rod(6)which has an immersed end and an exposed end and wherein the exposed end passes 13 over the plug(l l)between the left side of the cage(3)to the right side of the cage so that after 14 the concrete is poured and the plug(l l)is removed the exposed end passes over the 15 opening( 1 )left by removing the plug( 11). 16 40. The method of claim 39 wherein there is at least one second guide rod. 17 41. The method of claim 39 wherein the guide rod(6)is curved at the top over the plug( 11 )so 18 that after the plug(l l)is removed, top opening(l)to the passage(71)left by the plug(l l)may 19 be made under the guide rod(6)so that a second block with a bottom opening(4)may be 20 lowered over the at least one guide rod(6), with the bottom opening(4)being aligned with the 21 top opening(l)of the block and the at least one guide rod(6)fitting within the bottom 22 opening(4)of the second block. 23 42. The method of claim 31 wherein the step of preparing a mold having an interior surface 24 in the shape of the exterior of the outermost diameter of the block further comprises the step 25 of attaching a surfacing material(64)with a embedded portion and an exposed portion so that 26 the exposed portion is covered by the interior surface so that when concrete is poured, the 27 embedded portion is embedded within the block. 28 17

Inventors: DIAL TED C JR, DIAL, TED, C., JR.
Applicants: DIAL TED C JR, DIAL, TED, C., JR.
Application year: 1999
Main classification: E04B5
IPC codes: B22C9, B28B7, B28B13, B28B23, E02D29, E04B2