Abstract:
A masonry block system that employs blocks with unique surfaces, top and bottom, and a locking starter rail for placement below the block wall. The surfaces of the block and the shape of the starter rail are configured so as to lock together, providing a wall system. The system can either be mortarless wherein grout-like material is placed within the blocks to provide a monolithic system. A method of making and installing and various parts, such as the starter rail and block are also disclosed.

Description:
FIELD OF INVENTION  
       [0001]     This invention relates generally to the field of masonry block construction. More particularly, the invention relates to a masonry block system that employs a dry stacking interlocking block system with a unique starter device; various elements of the system; and, a method of installation.  
       BACKGROUND OF INVENTION  
       [0002]     Current methods and systems for masonry block construction have several advantages and disadvantages when compared to comparable cast-in-place concrete construction.  
         [0003]     Masonry construction does not typically require formwork, both in erection and teardown, that is found in concrete construction. Masonry construction also typically reaches design strengths quicker than comparable concrete construction. In general, masonry construction is less costly in material and labor costs than concrete construction.  
         [0004]     Conversely, masonry block construction typically requires, extensive layout time and labor to properly and accurately start the masonry construction. Further, the time, labor, and material, in the installation of block, including mortar, requires continual adjustment and verification that the block wythes are plumb, level, and in alignment. Often too, masonry block construction does not have the ultimate strength of concrete construction.  
         [0005]     Accordingly, there is a need for a masonry block system that offers advantages and improvements over current existing concrete and masonry block construction systems and methods.  
       SUMMARY OF INVENTION  
       [0006]     The present invention provides a stacking masonry block system.  
         [0007]     A first general aspect of the invention provides a system of constructing a masonry wall comprising:  
         [0008]     a plurality of blocks, configurable in stackable rows, said plurality of blocks having a top surface and a bottom surface, wherein a bottom surface of a first block is configured to match with the top surface of a second block; and  
         [0009]     a starter rail, configured to mate with said bottom surface, said rail including at least a first longitudinal planar surface and a second longitudinal planar surface wherein an angle between said at least two planar surfaces is acute.  
         [0010]     A second general aspect of the invention provides a stacking masonry block system comprising:  
         [0011]     a plurality of blocks, each having a configuration for interlocking with adjacently placed blocks;  
         [0012]     an elongate starter strip element, configured for placement on a foundation, adapted to interlock with said plurality of blocks placed thereon; and  
         [0013]     at least one system selected from the group consisting of a hardenable, flowable material placed within said plurality of blocks, and an exterior parging system.  
         [0014]     A third general aspect of the invention provides a method comprising:  
         [0015]     providing a plurality of blocks, configurable in stackable rows, said plurality of blocks having a top surface and a bottom surface, wherein a bottom surface of a first block is configured to match with the top surface of a second block; and  
         [0016]     providing a starter rail, configured to mate with said bottom surface, said rail including at least a first longitudinal planar surface and a second longitudinal planar surface wherein an angle between said at least two planar surfaces is acute.  
         [0017]     A fourth general aspect of the invention provides a starter element for use in a masonry block system comprising:  
         [0018]     a first elongate planar section;  
         [0019]     a second elongate section;  
         [0020]     a third elongate planar section, wherein said second and third sections are non planar with said first elongate planar section.  
         [0021]     A fifth general aspect of the invention provides an interlocking masonry unit comprising:  
         [0022]     a volume, defined by an overall height, width, and depth, said volume including a substantially vertical face, said volume including a first mating area and a second mating area, wherein said first mating area is configured to mate with a second mating area of an adjacently placed masonry unit, wherein said first mating area includes a surface that is non-parallel with said substantially vertical face.  
         [0023]     The foregoing and other features of the invention will be apparent from the following more particular description of various embodiments of the invention. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0024]     Some of the embodiments of this invention will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:  
         [0025]      FIG. 1  depicts an exploded perspective view of an embodiment of the interlocking masonry block system, in accordance with the present invention;  
         [0026]      FIG. 2A  depicts a top view of an embodiment of a locking starter device, in accordance with the present invention;  
         [0027]      FIG. 2B  depicts an end sectional view of an embodiment of a locking starter device, in accordance with the present invention;  
         [0028]      FIG. 3A  depicts a top view of a first embodiment of a masonry block, in accordance with the present invention;  
         [0029]      FIG. 3B  depicts an end view of the first embodiment of a masonry block, in accordance with the present invention;  
         [0030]      FIG. 3C  depicts a top view of a second embodiment of a masonry block, in accordance with the present invention;  
         [0031]      FIG. 3D  depicts an end view of the second embodiment of a masonry block, in accordance with the present invention;  
         [0032]      FIG. 3E  depicts a top view of a third embodiment of a masonry block, in accordance with the present invention;  
         [0033]      FIG. 3F  depicts an end view of the third embodiment of a masonry block, in accordance with the present invention; and  
         [0034]      FIG. 4  depicts a close-up sectional view of a portion of the interlocking masonry block system, in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0035]     Although certain embodiments of the present invention will be shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present invention will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of an embodiment. Although the drawings are intended to illustrate the present invention, the drawings are not necessarily drawn to scale.  
         [0036]     Turning to the figures, an exploded perspective view of an embodiment of the invention, is depicted in  FIG. 1 , while  FIGS. 2-4  show various details of the invention.  
         [0037]      FIG. 1 , shows a typical foundation footer  60 , often made of concrete, having a top surface  61 . Resting and bearing on the footer  60  is a system  10  of the invention. A starter element  20 , and a plurality of blocks  40  are placed together on the footer  60 . Upon satisfactory installation of the starter elements  20  and the blocks  40 , flowable, hardenable material  70  is subsequently placed within the cavities  45  (see e.g.,  FIG. 4 ) to bond the entire construct together. In this manner the system  10  is a mortarless, block-type construct having an increased strength.  
         [0038]     As shown in  FIGS. 1, 2A , and  2 B, the detail and configuration, of an embodiment of a starter strip  20  is shown. The starter strip  20 , or element, is typically longitudinal in shape comprised of a plurality of elongate, planar surfaces. The strip  20  includes a first, or base, longitudinal planar section  21 , and a second longitudinal planar section  22 A. There may be additionally a third longitudinal planar section  22 B.  
         [0039]     The base  21  is configured to lay upon the footer top  61 . The base  21  may include a plurality of openings  23  (e.g.,  23 A,  23 B, etc.) shaped to allow various connectors  30  to connect the strip  20  to the footer  60 . The openings  23  may be holes, slots, and the like. Similarly, the openings  23  may be spaced and configured to suitably attach the strip  20  to footer  60 . For example,  FIG. 2B  shows one method of attachment, wherein the connectors  30  are a plurality of screws  30  with threads  32  and washers  21  are drilled into the footer  60  in either pre-drilled holes or in a self-tapping manner so as to attach the strip  20  to footer  60 . Additionally, the openings  23  are available for allowing reinforcing bar, mechanical or electrical “stub ups”, and the like, to pass through the base  21 . The strip  20  may be made of a suitable rigid, or semi-rigid, material so that upon its installation the alignment and placement of strip  20  is maintained so as to allow accurately subsequent placement of the blocks  40  upon the strip  20 . For example, the strip  20  may be constructed of steel, galvanized material, stainless steel, cold-rolled steel, composite material, and the like.  
         [0040]     Various means and methods may be used to attach the strip  20  to the footer  60 . While  FIG. 2B  shows screws  30  as attachment means, the connectors  30  may be, for example, threaded rod (e.g., J-bolts, straight rod, etc.) embedded within the footer  60  and partially extending above the footer  60 . With this means of attachment, the strip  20  is attached to the plurality of threaded rod via nuts. Still alternatively, the strip  20  may be attached to the foundation  60  via a permanent adhesive (e.g., epoxy), and the like. In other embodiments, if the structural application allows, the strip  20  may be lightly pinned down, or laid in place, on the foundation  60 , with, for example, aesthetic, light construction, low walls.  
         [0041]     The second longitudinal planar section  22 A and the third longitudinal planar section  22 B are non-parallel with the base  21 . Additionally, the second and third planar sections  22 A,  22 B may be non-parallel to each other. Further, the second and third planar sections  22 A,  22 B may each form an acute angle, φ 1  and φ 2 , respectively, with the base  21 . Further, angles φ 1  and φ 2  may, or may not, be equal to each other.  
         [0042]     It should be apparent that various configurations of planar sections  21 ,  22 A,  22 B are part and parcel of the present invention. For example, any, or all of the sections  21 ,  22 A,  22 B may be less than entirely solid. That is the sections  21 ,  22 A,  22 B may have various openings. The sections  21 ,  22 A,  22 B may be lattice-like in their construction. The openings (not shown) may exist in order to allow the ready flow, or passage of flowable, hardenable material  70  throughout the system  10 ; to allow for additional elements (not shown) to pass through; to provide a lighter weight strip  20 ; and the like. Further, while the embodiment in  FIGS. 2A and 2B  depict sections  21 ,  22 A,  22 B that are smooth in construction, clearly appendages, projections, depressions, detents, and the like, can be added while not diverging from the intent of the invention.  
         [0043]     Similarly, various configurations of the strip  20  may be employed. The strip  20  can come in various lengths of straight sections. The strip  20  also can be on an angle for constructing corners. The strip  20 , thus, may be any angle. The strip  20  can be made on a curve, or multiple curves, of any radius. In these embodiments, the strip  20  can be rigid so that the shape and configuration is fixed. Alternatively, the strip  20  may be semi-rigid. That is, the strip  20  may be constructed so that its shape and configuration may user-adjustable in the field to any angulation and/or curvature. For example, the strip  20  may have gaps or other constructs that allows the installer to move, shape, and bend the strip  20  to the desired configuration. Once installed to the foundation  60 , the strip  20  provides a virtually errorless method for installing the subsequent blocks  40 .  
         [0044]     Turning to  FIGS. 3A-3F , several embodiments of blocks  40  are depicted in detail. While  FIGS. 3A and 3B  show, what could be termed a “typical” or “standard” block  40 , in accordance with the present invention,  FIGS. 3C and 3D  show a corner block  40  while  FIGS. 3E and 3F  show a capstone block  40 . While each embodiment of block  40  has its particular use, they share common aspects of the invention.  
         [0045]     The block  40  has an ultimate height  41 , depth  42 , and length  43 . The block  40  has two substantially vertical faces  44  which are exposed to view after installation. The block  40  includes a first mating area  46 . With the exception of the capstone block  40  (see  FIGS. 3E and 3F ), the block also includes a second mating area  47 . The block  40  includes a top bearing surface  51  and a bottom bearing surface  52 . Interstitial to the substantially vertical faces  44  is at least one opening  45 .  
         [0046]     Both first mating area  46  and second mating area  47  include a horizontal face  49 ,  50  and typically two canted (i.e., non-horizontal) surfaces  48 A,  48 B. Thus, the configuration of the blocks  40  are such that the first mating area  46  is shaped so as to mate, fit with the second mating area  47  of an adjacently placed block  40 . More specifically, the canted surfaces  48 A,  48 B and the horizontal faces  49 ,  50  are such that blocks can readily by placed by the installer easily. Similarly, the first mating area  46  is configured so as to mate, fit with the starter strip  20 , as well.  
         [0047]     The configuration of the strip  20  and blocks  40  make installation much quicker and easier than typical block construction. For example, continual checking for alignment, plumbness, etc. is not required as in the prior art, or at the least mitigated significantly. That is once the starter strip  20  is properly aligned and attached (fixedly or removably) to the footer  60 , all subsequently aligning activity is abolished, or significantly mitigated.  
         [0048]     Clearly, the block  40 , may be constructed of any suitable height  41 , depth  42 , and/or length  43 , depending on the particular requirements needed. For example, in the L-shaped embodiment as shown in  FIGS. 3C and 3D , the first length  43 A may be unequal to the second length  43 B.  
         [0049]     Similarly the mating surfaces  46 ,  47  need to be on both the top and bottom of the block  40 . For example, both a first mating surface  46  and second mating surface  47  are on some embodiments of block  40  (see e.g.,  FIGS. 3A-3D ). Contrastingly, the embodiment depicted in  FIGS. 3E and 3F , termed a “capstone”, have only a second mating surface  47  on the bottom of the block  40 . Other embodiments (not shown) may have only a first mating surface  46  on the top of the block  40 . That is the bottom of the block  40  may be substantially planar. Such an embodiment may be used as a header, or lintel, over a doorway or window opening in the system  10 .  
         [0050]     Optionally, reinforcing bar or other suitable reinforcement (not shown) may be located within, or extending through, the block  40 .  
         [0051]      FIG. 4  shows a close up sectional view of a portion of a wall installed under the current invention. A footer top  61  has the strip  20  installed thereon. A first block  40 A and second block  40 B are shown on top of each other and on the strip  20 , in turn. The configuration of the second and third planar sections  22 A,  22 B as they relate to the configuration of the entire first mating area  46  and the canted surfaces  48 A,  48 B, are such that upon the installation of the first block  40 A a void space  55  is created between the bottom of the face  50  and the strip  20 .  
         [0052]     Subsequent to the installation of the blocks  40  a flowable, hardenable material  70  is placed, or pumped, into the openings  45 . The material  70  may be grout, mortar, concrete, epoxy, and the like. In this manner, a monolithic construct is created between the block  40 , material  70  and the footer  60 .  
         [0053]     The material  70  thus can flow within all the openings  45  in all the blocks  40  as well as into the void  55  around the strip  20 . Thus, the material  70 , once hardened, converts the block  40  and strip  20  construct into a monolithic structure that is strong in tension, compression, in shear, and the like. The mating areas  46  and  47  add to this aforementioned strength. The strength between adjacent blocks  40 A,  40 B is greater.  
         [0054]     The shape of the starter strip  20  and the void  55  it creates under a first block  40 B are such that, once the void  55  is filled with the flowable, hardenable material  70 , and once the material  70  hardens, that the material  70  is prevented from moving in the vertical direction with respect to the adjacent blocks  40  in the system  10 . That is, the strip  20  and the void  55  together may allow the material  70  to act as a type of key in the system  10 . Therein, the system  10  is locked to the foundation  60  below.  
         [0055]     As shown in  FIG. 4 , an optional weep opening  58  may be located on at least one block  40 B so as to allow the escaping off of trapped air within the openings  45  during the placement of the material  70 . The weep opening(s)  58  may also serve as a viewing port for quality control purposes, to allow, for example, construction inspectors to visually confirm that the flowable material  70  has infiltrated all the openings  45  in the block  40 . The weep opening  48  may be singular, or plural, on each block  40  and may be located in any suitable location on the block  40 .  
         [0056]     Clearly, other variations and embodiments are part and parcel of the invention.  
         [0057]     One such variation is that the foundation  60  can be any suitable material for placement and support of the system  10 . The foundation  60  is not just limited to concrete footers and the like. Rather, the term as used herein may include suitably compacted gravel, soil, and the like. Similarly, the system  10  can be installed on a foundation  60  constructed specifically for this application. Contrastingly, the system  10  may bear directly on a preexisting concrete slab (e.g., slab on grade, elevated slab, etc.). Thus, the system  10  suits itself for new construction and/or renovation work; exterior and/or interior partitions; building construction and/or landscaping/sitework constructs; and, as a bearing or non-bearing construct. The system  10 , for example, can be used to create interior partitions (e.g., partial height, full height, etc.) in an existing building to parcel the existing space into subspaces.  
         [0058]     Another aspect of the invention allows for various material to be placed on the exterior of the walls of the system  10 . That is aesthetic; non-structural; and/or, structural materials and/or systems may be placed on the faces of the blocks  40  once installed. For example, the system  10  can be covered with paint, covered with waterproofing, furred out with a wall system, covered with parging, covered with insulation, or other systems.  
         [0059]     Alternatively, an exterior structural-type parging system (e.g., ⅛″ to ¼″ thick) may be added that provides a waterproofing, aesthetic, and/or interlocking strength aspect to the system  10 . One type of system that may be added is an Exterior Insulation and Finish System (EIFS), such as the system sold under the name, DRYVIT. Depending on the type of system that is placed on the exterior of the system  10 , flowable, hardenable material  70  may not necessarily be required to be placed internal to the block  40 . Thus, this exterior system may be used in lieu of, or in addition to, the flowable, hardenable material  70  placed within the blocks  40 . Alternatively yet, a hybrid system may be employed wherein the exterior parging system is used, while flowable, hardenable material  70  is only placed in select portions of the system  10 . For example, flowable, hardenable material  70  might only be placed where structurally necessary, such as in the corners of the construct and where buttresses, piers, and/or pilasters exist (i.e., locations of greater stress), while the exterior parging system is located on the exterior of the blocks  40  throughout.  
         [0060]     While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims.