Abstract:
A multi-purpose interlocking masonry unit includes support members extending from its lower surface and port depressions formed in its upper surface. Each masonry unit can be placed on top of a previously placed masonry unit. The interlocking masonry unit allows for the rapid creation of a wall that is substantially straight and aligned while minimizing the need to perform precise measurements and make alignment adjustments during the creation process. Bonding material can be poured through the resultant wall ports, creating a matrix pattern of bonding material throughout the wall, which results in a stronger more durable construction.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to an interlocking masonry unit. One embodiment of the invention comprises an interlocking masonry unit for use in mortared or similar wall construction which reduces the need for constant measurements and alignment, resulting in a wall with increased strength. 
       BACKGROUND OF THE INVENTION 
       [0002]    The creation of buildings by utilizing walls made of concrete or similar stonework is a popular method of construction. Many traditional masonry walls are created using masonry units commonly referred to as cinder blocks. A cinder block is a masonry unit in the shape of a rectangular prism with two vertical chambers. A wall is constructed by creating successive rows of cinder blocks. Often each row of cinder blocks is offset by half a block from the previous row to increase stability. Some form of mortar or similar bonding material is placed between each row of blocks to bond the blocks into a solid structure. 
         [0003]    One of the primary difficulties of creating cinder block walls is that constant measurements and adjustments must be made as the construction process is undertaken. Bonding material must be laboriously applied between each new block and all adjacent blocks. The craftsman must constantly adjust the wall as each block is placed to ensure that each row is level and straight. Failure to make constant adjustments often results in a wall that is uneven, non-level, angular, or otherwise unstable and not ascetically pleasing. This process is both time consuming for the craftsman and subject to significant human error. The resulting wall is also only as strong as the weakest bonded joint between two adjacent blocks. 
         [0004]    Therefore, what is needed is an interlocking masonry unit. The interlocking masonry unit should connect with adjacent masonry units in a standard way that reduces the need for precision and skill The interlocking masonry unit should also be designed to accept bonding material that is poured into the wall after each course of the wall is completed in order to reduce overall construction time. The interlocking masonry unit should also be designed to allow the bonding material to pour inside of and between the masonry units in both the horizontal and vertical dimensions to create a strong wall that is bonded together internally in all directions forming a matrix. Furthermore, other desirable features and characteristics of the present invention will become apparent when this background of the invention is read in conjunction with the subsequent detailed description of the invention, appended claims, and the accompanying drawings. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention provides an interlocking masonry unit that advantageously overcomes the aforementioned deficiencies. Each interlocking masonry unit may be placed in connection with an adjacent masonry unit in a standard manner that reduces the need for constant measurement and adjustment for alignment purposes. Additionally, bonding material may be poured as the wall is created so that the need for adjustment is clear to the craftsman before the units become permanently bonded together. The interlocking masonry unit also provides both horizontal and vertical cavities to accept bonding material in order to create a matrix of bonding material to increase the overall strength of the wall. 
         [0006]    The present invention is described more fully hereinafter with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description, and any preferred and/or particular embodiments specifically discussed. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and not limitation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The drawings contained herein illustrate an embodiment of the invention. The invention is not limited to the particular embodiment shown in the drawings. The embodiment shown is an example, and the invention is capable of many variations of said embodiment in the drawings; 
           [0008]      FIG. 1  illustrates a perspective view of the concave upper surface and a side surface of an interlocking masonry unit according to an embodiment of the present invention; 
           [0009]      FIG. 2  illustrates a perspective view of the concave lower surface of the interlocking masonry unit of  FIG. 1 ; 
           [0010]      FIG. 3  illustrates an end plan view of two vertically adjacent interlocking masonry units according to an embodiment of the present invention. The masonry unit may be offset by one half block as desired to increase the strength and stability of a stack or wall; 
           [0011]      FIG. 4  illustrates a top plan view of a complete and a partial horizontally adjacent interlocking masonry unit according to an embodiment of the present invention; and 
           [0012]      FIG. 5  illustrates perspective view of a wall comprising multiple masonry units according to an embodiment of the invention.  FIG. 5  also shows the use and placement of rebar reinforcement in the wall system for added strength. 
       
    
    
       [0013]    The first digit of each reference numeral in the above figures indicates the figure in which an element or feature is most prominently shown. The second digit indicates related elements or features, and a final letter (when used) indicates a sub-portion of an element or feature. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0014]      FIGS. 1 and 2  illustrate a masonry unit according to a preferred embodiment of the invention, and is shown generally at reference numeral  100 .  FIG. 1  illustrates a perspective view of the concave upper surface and a side surface of the masonry unit  100 . The masonry unit  100  comprises a generally rectangular prism shape with a concave upper surface  10  as shown in FIG.  1 ., a concave lower surface  20  as shown in  FIG. 2 , two side surfaces  11  as shown in  FIG. 1 , and two end surfaces  30  as shown in  FIG. 3 . One skilled in the art will recognize that any three dimensional object with a rectangular prism shape generally comprises six surfaces. The surface names, as used throughout the application, are chosen for purposes of designation rather than functionality and should not be considered limiting. The purpose of the concave shape of the upper surface  10  and lower surface  20  is discussed below in reference to  FIG. 3 . 
         [0015]    The masonry unit  100  comprises one or more central vertical cavities  12 , as shown in  FIGS. 1 and 2 . The central vertical cavities  12  should extend between the lower surface  20  and the upper surface  10  of the present invention and should be capable of accepting bonding material. In the preferred embodiment, two central vertical cavities  12  are employed, and each of the central vertical cavities  12  comprise the same shape mirrored about an axis passing through the center of the unit and perpendicular to the side surfaces  11 . In the preferred embodiment, the central vertical cavities  12  comprise a rounded triangular shape, however, many central vertical cavity  12  shapes could be substituted. When two or more interlocking masonry units  100 ,  100 ′ are placed in a vertically adjacent position relative to one another, also referred to hereinafter as a stack as shown in FIG.  3 ., the central vertical cavities  12  of each masonry unit should be generally aligned with the central vertical cavities  12  of the other units. So long as the central vertical cavities  12  of each unit are generally the same shape and are generally aligned, any bonding material poured into a central vertical cavity  12  of the uppermost unit  100  will also pour through the corresponding central vertical cavity  12  of each unit below in the stack due to the force of gravity. This allows a craftsman to quickly create a wall by stacking the masonry units, one on top of one another, and then pouring bonding material through each vertical cavity as the wall is completed and judged to be in the proper shape and alignment. In the preferred embodiment, the central vertical cavities  12  are surrounded by a sloped edge  12 A as shown in  FIGS. 1 and 2 , preferably at or near a forty five degree angle from the horizontal plane, to act as a funnel creating a larger void between the upper and lower masonry units, thus assisting the bonding material in its movement into the lower portions of the stack. 
         [0016]    As shown in FIG.  2 ., the masonry unit  100  comprises a plurality of support members  21  projecting vertically out from the lower surface  20  of the masonry unit. Preferably, eight support members  21  are employed, however, a greater or fewer number of support members  21  can be employed. As shown in  FIG. 1 , the masonry unit comprises a plurality of receiving port depressions  13  each projecting vertically into the upper surface  10  of the masonry unit  100 . Preferably, eight receiving port depressions  13  are employed. Each receiving port depression  13  can be shaped and positioned to be capable of receiving a corresponding support member  21  from another masonry unit. As such, multiple masonry units can be stacked one on top of another. When creating the stack, the support members  21  of the upper masonry unit are received by the receiving port depressions  13  on the upper surface  10  of the masonry unit immediately below it. In this manner, each masonry unit is effectively interlocked into position relative to the masonry units below. Absent manufacturing defects or variable terrain, the resulting stack is straight and level without requiring the user to undertake efforts to adjust or otherwise level the stack. As variable terrain and manufacturing irregularities are possible, the user can rapidly create a stack and quickly observe and correct any alignment concerns prior to pouring bonding material through the vertical cavities. Preferably, each receiving port depression  13  is larger than the support members  21  to allow the user to make minor adjustments to the wall as it is completed. 
         [0017]    In a preferred embodiment, each end surface  30  as shown in  FIG. 3  further comprises two end projections  14 . As shown in FIG.  4 ., the end projections  14  can be shaped and positioned so that when two interlocking masonry units are placed in a horizontally adjacent configuration, an intermediate vertical cavity  40 , as shown in  FIG. 4 , extending between the masonry units is created. When the masonry units are stacked in rows, the intermediate vertical cavity  40  can accept bonding material. So long as the masonry units are not offset, the bonding material can be capable of poured through an intermediate vertical cavity  40 , as shown in  FIG. 5 , that is placed in a higher position in the stack to intermediate vertical cavities  40  that are placed lower in the stack due to the force of gravity. However, even in an offset configuration, as can be seen in  FIG. 5 , the bonding material can be poured into each intermediate vertical cavity  40  from the central cavity  12  above it, due to the shape and positioning of the central cavities  12 . Each of the end projections  14  include a sloped edge  14 A, as shown in  FIG. 1 , preferably at or near a forty five degree angle from the horizontal plane, to act as a funnel and assist the bonding material in its movement into the lower portions of the stack. The end projections  14  should be omitted on the end surface  30  of any masonry unit that is to be used at the corner of a wall. It should also be noted that, in the preferred embodiment, portions of each block end come in contact with an adjacent block. This allows for proper alignment and spacing which maximizes amount of bonding material to attach between each unit to strengthen the bond. It should also be noted that, preferably, the shape of the intermediate vertical cavity  40  is irregular. This configuration increases the surface area available for the bonding material to attach to for a stronger bond. This configuration also ensures that the end projections  14  each attach around the cured bonding material contained in the vertical cavity  40 , which further reduces the possibility of a breach in the wall, even if the bonding material should become separated from the associated masonry unit. 
         [0018]    As shown in  FIGS. 1 and 4 , the masonry unit  100  can include one or more vertical depressions  15  in one or both of the side surfaces  11 . Preferably, each vertical depression  15  has a width greater than one-half inch and less than two inches. Preferably, each vertical depression  15  projects into the masonry unit  100  between one-half inch and two and a half inches, and each vertical depression  15  also preferably extends down the entire side surface  11  of the masonry unit. When crafted to these preferred dimensions, each vertical depression  15  is capable of accepting a wall stud. The vertical depressions can further comprise a plurality of stud support notches  17 , as shown in  FIGS. 1 and 2 . Each of the stud support notches  17  can be capable of accepting a peg to hold a wall stud in place. When a wall is finalized, a wall stud can be inserted into the vertical depression  15  and secured in position by means of plurality of pegs or similar items hammered or screwed into the stud support notches  17 . In an alternate embodiment, no support notches  17  are provided and the wall studs can be secured by a toggle bolt or other securing means. This allows the user to create a wooden wall, capable of accepting drywall or similar finishing material without the structure that is typically associated with a standard wall. Referring to  FIG. 4 , the end projections  14  may also be shaped and positioned to create a vertical depression  15  in the side surface  11  between two horizontally adjacent interlocking masonry units  100 ,  100 ″ that are capable of accepting a wall stud. This ensures that in the case of stacked rows where one or more rows are offset by half a masonry unit from one another, the vertical depression  15  in the side surface  11  of a masonry unit lines up with the vertical depression  15  created between two horizontally adjacent masonry units on a different row. This allows a wall stud to be accepted into all of the rows at once. Preferably, the vertical depressions  15  are positioned to create a distance of eight inches between the center of each wall stud and the center of the horizontally adjacent wall studs, once said wall studs are accepted. This allows the user to easily attach standard building materials to the wall studs. 
         [0019]      FIG. 3  illustrates an end plan view of two vertically adjacent interlocking masonry units  100 ,  100 ′. In the preferred embodiment, the concave upper surface  10  of the lower masonry unit and the concave lower surface  20  of the upper masonry are shaped to create a horizontal cavity  31  which extends between the two masonry units. The horizontal cavity  31  is capable of accepting bonding material poured from upper rows through the vertical cavities and channeling the bonding material horizontally between two rows in the wall. The channel created by the horizontal cavity  31  and the vertical cavities  12  create a matrix of cured bonding material which increases the overall strength of the wall in relation to standard cinderblock walls. The channel created by the horizontal cavity  31  also allows bonding material to pour into the intermediate vertical cavities  40  in cases where the rows of the wall are offset. An end surface  30  of any masonry unit that is to be used at the corner of a wall can include an additional projection on the upper surface  10  and the lower surface  20  capable of closing the horizontal cavity  31  and vertical cavity  40  preventing any bonding material from escaping from the channel created by the horizontal cavities  31  of the masonry units  100 ,  100 ′ in the wall. 
         [0020]    In a preferred embodiment, the upper surface  10  further comprises a plurality of upper projections  32  as shown in  FIG. 3 . The upper projections  32  can accept one or more reinforcing elements  16 , as shown in  FIG. 1  and  FIG. 5 , such as concrete reinforcing bar, also known as rebar, and/or similar items. The vertical channels created by the central vertical cavities  12  are also capable of accepting one or more reinforcing elements  16 . The presence of the reinforcing elements  16  increases the overall structural integrity of the resultant wall after the bonding material is poured inside and allowed to cure. The matrix of vertical and horizontal channels associated with a wall constructed with the interlocking masonry units, as described herein, along with associated reinforcing elements  16 , creates a structural integrity that is significantly increased over a standard cinder block wall. 
         [0021]    In a preferred embodiment, the masonry unit  100  has sharp edges  35  at the outer perimeter at the top and bottom and on both ends of the masonry unit  100 , as shown in  FIGS. 1 and 2 . The sharp edges  35  form one-half of a mortar seam. The edge  35  slopes inward, toward the center of the masonry unit  100  to form a V or pinch point  45 , as shown in  FIG. 4 , between masonry units  100 ,  100 ″, when the units are stacked end to end and/or one on top of the other. This pinch point  45  preferably should be approximately one-sixteenth to one eighth inch in width. This pinch point  45  is shaped similar to a funnel to guide the bonding material from a wide area or space to the narrow space where the grit, sand and gravel of the bonding material fill in, forcing out air from the masonry units and sealing the space, bonding the units together. In addition, the masonry unit  100  can have sloped, concave outer edges  34 , as shown in  FIG. 3 . 
         [0022]    In a preferred embodiment, each end projection  14  further comprises a bumper projection  33 . As can be seen in  FIG. 4 , each bumper projection  33  is shaped and positioned to come in contact with a bumper projection  33  of an equivalent horizontally adjacent interlocking masonry unit when the masonry units are being placed by the user. In this manner, the user may place each masonry unit, verify the bumper projections  33  of each masonry unit are properly touching, and thereby verify that the row of masonry units being created is level and aligned. The bumper projections  33  hold the blocks of the masonry units apart a pre-determined distance, as shown at reference numeral  45  in  FIG. 4 . Preferably, the bumper projections  33  create a space  45  of approximately one-sixteenth to one-eighth inch wide. This space  45  lets the air out when the masonry units are being filled with bonding material. The grit, rock and sand that is part of the bonding material fills the internal block voids are stopped from exiting at this point 
         [0023]      FIG. 5  illustrates perspective view of a wall comprising multiple masonry units according to a preferred embodiment of the invention. A method of assembling a wall comprising interlocking masonry units as depicted in  FIG. 5  is now more fully described. A row of interlocking masonry units can be created by placing a plurality of interlocking masonry units on a prepared surface in a manner that causes the end surface  30  of each masonry unit to come in contact with an end surface  30  of one or more adjacent masonry units. Subsequent rows of interlocking masonry units can be positioned on top of the previously created row of interlocking masonry units by placing the support members  21  of the masonry units in the subsequent row into the receiving port depressions  13  of the previously placed row. This process can be repeated until a wall or structure of the desired height is created. Reinforcing elements  16  can be placed into the horizontal cavities  31  between each row. Depending on the embodiment, the user may shift each subsequent row by half of the length of a masonry unit in the horizontal axis from the previously placed row to increase the stability of the resultant wall. The reinforcing elements  16  can be placed in the horizontal cavities  31  prior to placing any associated corner units. Reinforcing elements  16  should also be placed into the central vertical cavities  12  and  40  of each masonry unit for greater structural integrity. Bonding material can be poured into the vertical cavities and allowed to spread and seep into the horizontal cavities to create a matrix of bonding material throughout the cavities of the wall. A mechanical means may be employed to vibrate and to assist the bonding material in its spread throughout the matrix of cavities in the structure. The bonding material should then be allowed to cure in the wall. In an alternate embodiment, bonding material can be poured into the cavities after each row is positioned. 
         [0024]    While the present invention has been described above in terms of specific embodiments, it is to be understood that the invention is not limited to these disclosed embodiments. Many modifications and other embodiments of the invention will come to mind of those skilled in the art to which this invention pertains, and which are intended to be and are covered by both this disclosure and the appended claims. The foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the following claims and equivalents thereof.