Patent Publication Number: US-6705057-B2

Title: Modular block system and method of construction

Description:
FIELD OF INVENTION 
     The present disclosure relates to construction blocks and a system of construction utilizing the construction blocks. More specifically, the disclosure relates to a specialized construction block, construction block engaging gaske and a system of construction utilizing the construction blocks and gaskets. 
     BACKGROUND 
     Over the centuries, construction blocks of various shapes and sizes have been a mainstay in the construction of various structures and dwellings. Ancient builders used building blocks hewn from solid stone. In most cases, the predominate shape of these construction blocks has been the rectangle, or a variation thereof. In other cases the shape of the block is dictated by the architectural function for which the block is needed. For instance an arch or lintel is needed to create a window opening and a cornice is needed to protrude out from the plane of the exterior wall in order to direct rainwater away from the building. Yet in nearly all cases, the faces of each adjacent block are flat and in parallel planes. Structures built using these construction blocks had the advantage of durable construction, as is evidenced by the conditions of many archeological monuments today. 
     Over the ages, builders have continued the tradition of carving and fabricating construction blocks from a variety of materials. Today, construction blocks are typically formed as bricks, concrete blocks, cinder blocks and tiles. Today&#39;s modern construction blocks have the added benefits that in addition to being very durable, the construction blocks are relatively inexpensive to manufacture, can be manufactured in mass quantities for relatively uniform installation and are virtually maintenance free. 
     One trend in the construction industry is the use of construction blocks with architecturally finished details for building construction and specialized architectural structures, such as free standing walls, arches, cornices, columns, pilasters, jambs, beams, ceilings, floors, chimney pieces, tiers, brackets, capitals and other special structures. Through the use of these construction blocks, structures can be created with a finished appearance, as wells as structures that require less materials and labor to produce an aesthetically pleasing result. As a result, significant cost savings can be realized. In addition, these specialized construction blocks are often formed with interior chambers that form a hollow internal network in the finished structure. This internal network can be utilized in various manners. For instance, if added strength is desired, the internal network can be filled with concrete in order to secure the blocks together. If increased insulating properties are desired, the internal network can be filled with an insulating foam. Alternatively, a mixture of insulating material and cement can be introduced into the hollow internal network to add both strength and insulation at once. 
     Despite the advances in construction block manufacture and composition, the method of construction block installation has remained essentially the same over the years. Skilled workers must arrange and align individual blocks in the construction array to form the completed structure while applying mortar or other material to seal the joints between the blocks to create a finished appearance. However, despite modern techniques for construction block production, it is impossible to mass produce the blocks with 100% accuracy. As a result, slight variations in the vertical and horizontal dimensions of the construction blocks occur. As a result, workers on the site must manipulate the construction blocks to achieve an optimal alignment between the construction blocks that make up the structure to create a uniform mortar joint. As many of the construction blocks used today are bulky and heavy, this manipulation process can be time consuming and arduous, and can even result in injury to workers. 
     Therefore, construction materials and a method of construction are needed that allow for the efficient and cost effective construction of an aesthetically pleasing and structurally sound finished structure. Through the of the construction blocks, gaskets and method described in the present disclosure, a user will be able to cost-effectively produce a finished structure with consistent joint spaces between the construction blocks, while at the same time compensating for minor irregularities in the engaging faces of the construction blocks. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a three-dimensional view illustrating an embodiment of the construction block described herein; 
     FIG. 1A is a cutaway view of the block of FIG. 1 further illustrating the lifting rods; 
     FIG. 2 is a three-dimensional view illustrating the construction of a construction array using the blocks, gaskets and construction method described herein; 
     FIG. 3 is a partial cutaway view of an embodiment of the bed gasket described herein; 
     FIG. 4 is a view of an embodiment of the butt gasket described herein; and 
     FIG. 5 is plan view of two blocks of the construction array of FIG. 3 illustrating one possible placement of the butt gasket. 
    
    
     DESCRIPTION 
     The following terms should be given the following meanings in the specification and attached claims: 
     a bed joint shall mean the structure, typically in the horizontal plane, formed when any two load bearing faces of two or more construction blocks are positioned adjacent to one another in a construction array; 
     a butt joint shall mean the structure, typically in the vertical plane, formed when any two engaging faces of two or more construction blocks are positioned adjacent to one another in a construction array; 
     a construction array shall mean any two or three dimensional configuration of construction blocks, regardless of the pattern of construction, useful in creating a structure; 
     a construction block shall mean any block or other material suitable for use in forming a construction array, regardless of the shape, size or composition of the block or material; and 
     a structure shall mean any article manufactured from a construction array such as, but not limited to, interior and/or exterior walls, arches, cornices columns, pilasters, jambs, beams, ceilings, floors, chimney pieces, tiers, brackets, capitals, free-standing walls and any architectural details needed to create the same; 
     FIG. 1 illustrates a construction block  10  typical of the present disclosure. The block is shown as generally rectangular in shape. As is the standard in design of construction blocks, the block  10  has 6 sides, or faces: a first load bearing face  12  (the upper face), a second load bearing face  14  (lower face), a first engaging face  16  and a second engaging face  18  (the side faces), and an interior face  20  and an exterior face  22 . The interior of the block  10  may be solid, or may be hollow. In the instance where the interior of the block  10  is hollow, the first  12  and second  14  load bearing faces, the first  16  and second  18  engaging faces and the interior  20  and exterior  22  faces define at least one block passage  30  in the interior of the block  10 . The block passage  30  may extend throughout the vertical length of the block  10 , as defined by the length of the first  16  and second  18  engaging faces, to create top  32  and bottom  34  openings, or may terminate before extending throughout the vertical length of block  10 , creating only a top opening  32 , or only a bottom opening  34 . In addition, there may be additional side openings  36  and  38  in the engaging faces  16  and  18 , extending into the block passage  30 . 
     FIG. 1 shows block  10  with one block passage  30 , a top opening  32 , a bottom opening  34  and two side openings  36  and  38 . The top  32 , bottom  34 , and side  36  and  38  openings allow the formation of an internal network in the construction array. Through this internal network, any given block opening in one construction block may communicate with any other block opening in an adjacent construction block in the construction array if the blocks  10  are in proper allignment. This communication allows the construction blocks in the construction array to receive concrete to reinforce the array, or insulating material to provide superior insulating properties to the construction array, or an insulating concrete providing both reinforcement and insulation. 
     FIGS. 1 and 1A also illustrates the lifting rod  40 . The lifting rod  40  is designed to aid in the placement of the construction block  10  into the construction array. For example, a crane or other lifting device, can be used to lift and move the construction block into an initial alignment. This is particularly advantageous when heavy construction blocks are used that are too heavy to be easily manipulated manually. The number and placement of the lifting rod(s)  40  is dependent on the size and structure of the particular construction block  10  used. The number and placement of the lifting rod(s)  40  is such that a the weight of the construction block can be supported by the lifting rods  40  and the construction block  10  can be transported into its initial alignment in the construction array. The lifting rod(s)  40  may be fashioned from any material capable of supporting the weight of construction block  10 , such as steel. In addition, the lifting rod(s)  40  serve as reinforcing members of the construction block  10  and of the construction array if material is introduced into the block passage  30 . In order to minimize interference during block construction, the lifting rod(s)  40  are contained between the planes formed by the first  12  and second  14  load bearing faces of the construction block. 
     The lifting rod(s)  40  may extend from any one face of the construction block to a different face of the construction block, thereby extending across the block passage  30 . Alternatively, the lifting rod(s)  40  may extend from any one face of the construction block to the same face of the construction block, without extending completely across the block passage  30 . In this embodiment, the lifting rod(s)  40  form a closed configuration, with both ends of the closed configuration being secured in the same face of the construction block. 
     FIGS. 1 and 1A show an embodiment of block  10  with two lifting rods  40 . The lifting rods  40  are shown extending from within the interior side of the inner face  20  to within the interior side of the outer face  22 . In this embodiment the lifting rods  40  extend across the block passage  30 . However, the lifting rods  40  may be positioned so that they extend from within any one face of the construction block  10  to any other face of construction block  10 . Alternatively, the lifting rods  40  may simply be a closed configuration extending from within one or more faces of construction block  10  without extending into any other face of construction block  10 . For example, the lifting rods  40  may be one or more loop structures embedded within the inner  20  and/or outer  22  faces without extending completely across the block passage  30 . 
     The corners of construction block  10 , which are formed by the intersection of the six faces of the block  10  described above, are substantially right angles. The presence of right angles on the construction block  10  simplifies the production process for the blocks  10 , decreasing the unit cost of the finished blocks. Prior construction blocks have incorporated beveled corners. These beveled corners were required to form an opening to receive mortar, or other material, to seal the joints between the construction blocks in the construction array and to present a professional appearance to the finished structure. The construction blocks  10 , when used in the construction method to be described below, obviate the requirement for beveled corners through the use of bed gaskets and butt gaskets (described below) at the block joints. The spacing between adjacent blocks created by these gaskets forms a uniform opening to receive the mortar, or other material, along the exterior edge of the gasket. The uniformity of the opening has the added advantage that a finished, professional joint is produced once the mortar, or other material, is applied. 
     The present disclosure also teaches a unique method which utilizes the construction blocks and gaskets taught by the present disclosure to form a construction array. The construction blocks may be arranged in the array in any manner desired. FIG. 2 shows an illustrative construction array to exemplify the novel construction method, illustrating a staggered configuration of blocks. The first course of construction blocks in the array is shown as blocks  10 A,  10 B and  10 C. The second course of construction blocks in the array is shown as blocks  10 D and  10 E. The juxtaposition of blocks  10 A,  10 B,  10 C,  10 D and  10 E in the construction array forms the bed joints  100  and the butt joints  110 . Aside from mortar or other material, generally in the construction methods taught by the prior art, there is no physical barrier separating the construction blocks comprising the first course and the construction blocks comprising the second course of the array. As a result, once a large construction block is initially positioned in the array, it is difficult to adjust the block to attain optimal alignment for final positioning within the array due to the frictional forces generated as the blocks grate against one another. 
     The present disclosure teaches the placement of bed gasket  120  between the construction blocks forming the bed joints  100  and a butt gasket  130  between the construction blocks forming the butt joints  110 . The bed gasket  120  serves several different functions, including correcting small irregularities in the load bearing surfaces  12  of the construction blocks  10 A- 10 E incorporated into the construction array, absorbing and dissipating small shocks to the structure, and allowing the efficient manipulation of construction blocks in the construction array. Therefore, the bed gasket  120  can be any device which provides the following: 
     1. one face to provide for increased frictional characteristics and compressibility, allowing the bed gasket to adhere to the first load bearing faces  12  of the construction blocks in lower course of the construction array, to correct any irregularities in the first load bearing faces  12  and to provide a mechanism to absorb shock to the structure; and 
     2. one face to provide for decreased frictional characteristics, allowing the second load bearing faces  14  of the construction blocks in the upper course of blocks to slide against the bed gasket. 
     FIG. 3 illustrates a bed gasket  120 . The bed gasket  120  comprises two faces, a lower face  122  which provides increased frictional characteristic, and an upper face  124 , which provides for decreased frictional characteristics. It is preferred that the material comprising the lower face  122  be compressible under the weight of the construction block  10 , while the material comprising the upper face  124  be resistant to compression under the weight of the construction blocks  10 . In this embodiment, the lower face  122  and the upper face  124  comprise two distinct materials which are bonded together to form the finished bed gasket  120 . The inventors have found that neoprene rubber as the lower face  122  and high-density plastics as the upper face  124  act as a superior bed gasket  120 , but bed gasket  120  may comprise different materials. For example, alternate materials for the lower face  122  include, but are not limited to, natural rubber, synthetic rubber compositions, expanded polystyrene, neoprene, cotton webbing and carpet. Alternate materials for the upper face  124  include, but are not limited to, low and medium-density plastic, steel, other metals and hardwoods. In addition both the upper face  124  and the lower face  122  may incorporate faces with only decreased frictional characteristics. 
     Bed gasket  120  may also be of unitary construction, providing the bed gasket  120  is composed of material capable of providing a lower face  122  with increased frictional characteristics and an upper face  124  with decreased frictional characteristics as described above. Alternatively, the bed gasket  120  may be of a 3-layer construction, with the lower face and upper face being composed of a material providing decreased frictional characteristics as described for the lower face  122 , and the middle layer being composed of a material, such as, but not limited to low and medium-density plastic, steel, other metals and hardwoods, to impart strength to the bed gasket  120 . These two embodiment of the bed gasket  120  may be useful when the decreased frictional characteristics described above for the upper face  124  are not required (such as the case when smaller construction blocks are being used). 
     The butt gasket  130  may also incorporate faces with increased and decreased frictional characteristics as described above for the bed gasket  120 , but alternatively, may incorporate faces with only decreased frictional characteristics and shock absorbing properties. FIG. 4 illustrates one embodiment of butt gasket  130 . In this embodiment, the butt gasket  130  comprises a lower face  132  and an upper face  134 , both providing decreased frictional characteristics. The butt gasket  130  may be manufactured from the same materials as the lower face  122  of the bed gasket  120 , or may be composed of a different material. 
     The bed  120  and butt  130  gaskets can be of varying size and thickness depending on the construction block used. The thickness and/or width of the bed  120  and butt  130  gaskets may increase as the size of the construction block increases. Additionally, the thickness and/or width of the bed  120  and butt  130  gaskets may increase or decrease in order to produce a joint of the desired width, the width of the joint being dictated by aesthetic and structural requirements. The composition of the bed  120  and butt  130  gaskets may also vary depending on the size of the construction block used. These modifications are well within one of ordinary skill in the art in the construction field. 
     Again referring to FIG. 2, this embodiment illustrates the placement of bed gaskets  120  and butt gasket  130  in the construction array. Bed gasket  120  is placed on the first load bearing faces  12  of blocks  10 A,  10 B and  10 C, with the lower face  122  contacting first load bearing faces  12  of said blocks. In this configuration, the decreased frictional characteristics of lower face  124  allow bed gasket  120  to engage the load bearing faces  12  of blocks  10 A,  10 B and  10 C. The construction blocks of the second course (blocks  10 D and  10 E in FIG. 3) of the construction array are now ready to be placed in the array. Blocks  10 D and  10 E are placed so that the upper face  124  of bed gasket  120  engages the second load bearing faces  14  (as shown in FIG. 1) of blocks  10 D and  10 E. As a result, bed gasket  120  will not move significantly from its original position when blocks  10 D and  10 E are placed on the bed gasket  120  due to the increased frictional characteristics of the lower face  122  of bed gasket  120 . Furthermore, blocks  10 D and  10 E can be easily manipulated by workers by sliding the blocks  10  along the upper face  124  due to the decreased frictional characteristics of the upper face  124  of bed gasket  120 . 
     Also illustrated in FIG. 2 is butt gasket  130 . Butt gaskets  130  are placed between the engaging faces of the blocks in the construction array. Specifically, butt gaskets  130  are placed between the vertical engaging faces  18  of the construction blocks  10 A- 10 E of the construction array. FIG. 5 further illustrates the placement of the butt gaskets  130 . FIG. 5 is a top view of the butt joint  110  formed by blocks  10 D and  10 E in FIG.  2 . Two butt gaskets  130  are shown positioned between the second engaging face  18  of block  10 D and the first engaging face  16  of block  10 E. The two butt gaskets  130  are positioned vertically along the outer edges of the engaging faces  16  and  18 , although positioning horizontally across the top and bottom the engaging faces  16  and  18  is an option. 
     Although the above discussion specifically described the placement of bed gaskets  120  and butt gaskets  130  in a simply construction array, the same principles can be applied for use in any construction array to achieve the benefits described. 
     The novel construction method described herein provides many benefits not heretofore appreciated in the art. As described above, using the system described, workers will be able to easily manipulate even construction blocks of large size with greatly reduced effort by virtue of the reduced frictional characteristics of the upper face of the bed gaskets. This is accomplished because the construction blocks can slide along the upper surface of the bed gasket, which greatly reduces the friction encountered when sliding the construction blocks against each other. This offers the advantages of decreased construction times (and therefore, reduced labor cost) and decreased risk of worker injury. In addition, the result is a more aesthetically pleasing finished product, since finer manipulation of the construction blocks is possible allowing optimal final placement of the blocks. The use of the bed and butt gaskets will also provide for a more uniform mortar joint throughout the finished structure. This uniform mortar joint can be provided using construction blocks with perpendicular corners as described above. As a result, the construction blocks can be manufactured without beveled corners, reducing the cost of producing the blocks, and reducing the variations of block types that must be produced. 
     The bed gaskets and butt gaskets also provide a cushion between the construction blocks in the construction array by virtue of the composition of the gaskets themselves. As described above, the lower face of the bed gasket and the butt gasket are composed of material that offers many of the same properties as rubber, and may be composed of rubber. Therefore, the gaskets provide an amount of structural cushioning and shock absorption without interfering with the structural characteristics of the finished structure. The bed and butt gaskets will also provide a type of seal between the construction blocks in the finished structure. This extra seal will give superior insulating characteristics to the finished structure, as well as providing an additional barrier to liquid penetration. 
     The description is intended to be illustrative of the construction blocks and system of construction described herein. It should be appreciated that various modifications could be made in the construction blocks, gaskets and system of construction utilizing the construction blocks and gaskets which remain within the scope and teaching of the instant disclosure. The details given herein are to be interpreted as illustrative only and not in a limiting sense.