Patent Publication Number: US-8973322-B2

Title: Masonry units and structures formed therefrom

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation-in-part of U.S. patent application Ser. No. 14/156,989, filed on Jan. 16, 2014, which claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 61/753,050, filed on Jan. 16, 2013, the entire contents of each of which are incorporated herein by reference. 
    
    
     1. TECHNICAL DESCRIPTION 
     The present disclosure relates to masonry units and structures formed therefrom, and more particularly, to building blocks and systems capable of accommodating a belting or cage arrangement in the construction of buildings, structures or the like. 
     2. BACKGROUND OF RELATED ART 
     Masonry units are made of various suitable materials, such as, for example, concrete, to form generally rectangular shaped blocks that can be stacked on top of one another to act as a building material for various load-bearing structures. Concrete masonry units are usually reinforced with rebar to provide the structure greater resistance to lateral forces. Concrete masonry units, however, rely heavily on mortar joints to join individual units to one another. Accordingly, it is desired to have masonry units or concrete blocks that are capable of forming a structure with enhanced strength and stability compared to that provided by concrete masonry units in the prior art. 
     SUMMARY 
     In an aspect of an embodiment of the present disclosure, a masonry unit for constructing built structures is provided. The masonry unit includes a rectangular shaped base having a front edge and a rear edge. The front edge and the rear edge each include a recess formed therein configured for disposal of a vertically disposed reinforcing material. A pair of spaced apart sidewalls extends perpendicularly from the base and along a length of the base. The sidewalls and the base together define a cavity configured for disposal of a fill material. A pair of spaced apart bridges is supported on the base configured for disposal of lengths of a horizontally disposed reinforcing material. The bridges extend transversely between the sidewalls and each have a height less than a height of the sidewalls. The base defines a hole therethrough disposed adjacent one bridge of the pair of spaced apart bridges. 
     In embodiments, a first bridge may have a first side surface and a second side surface, opposite the first side surface. The recess of the front edge may be disposed adjacent the first side surface and the hole may be disposed adjacent the second side surface such that the first bridge is disposed between the recess of the front edge and the hole. The masonry unit may include a channel extending longitudinally along the base from the recess of the front edge to the hole and extending transversely through the first bridge. 
     In embodiments, the recesses may have a semi-circular profile. In further embodiments, a first bridge of the pair of spaced apart bridges may be adjacent a first recess of the recesses and a second bridge of the pair of spaced apart bridges may be adjacent a second recess of the recesses. It is contemplated that the first recess may occupy an entire area defined between the sidewalls, the first bridge, and the front edge, and the second recess may occupy an entire area defined between the sidewalls, the second bridge, and the rear edge. 
     In some embodiments, each sidewall may include an outer surface and an inner surface. The outer surfaces may be disposed in parallel relation to one another and the inner surfaces may be angled relative to one another. 
     It is envisioned that each bridge may have an upper surface that defines a pair of spaced apart grooves each configured for disposal of reinforcing material. The spaced apart grooves may have a semi-circular configuration. In embodiments, the upper surface of each bridge may be spaced from the base to define a height of each bridge. 
     In another aspect of an embodiment of the present disclosure, a masonry structure is provided. The masonry structure includes a plurality of masonry units. Each masonry unit includes a rectangular shaped base having a front edge and a rear edge. The front edge and the rear edge each include a recess formed therein. A pair of spaced apart sidewalls extend perpendicularly from the base and along a length of the base. The sidewalls and the base together define a cavity configured for disposal of a fill material. A pair of spaced apart bridges is supported on the base. The bridges extend transversely between the sidewalls and each has a height less than a height of the sidewalls. The base defines a hole therethrough disposed adjacent a first bridge of the pair of spaced apart bridges. The masonry units are disposed adjacent to one another such that the front and rear edges of adjacent masonry units are in abutting engagement and form an enclosed passageway defined by the recesses of two adjacent masonry units. A plurality of first reinforcing bars are arranged in parallel to one another to form a cage. The cage is supported by the bridges of the masonry units and is disposed in the cavities of the masonry units. The masonry structure further includes at least one second reinforcing bar disposed in the enclosed passageway of two adjacent masonry units. 
     In embodiments, a first bridge of the pair of spaced apart bridges has a first side surface and a second side surface, opposite the first side surface. The recess of the front edge may be disposed adjacent the first side surface and the hole may be disposed adjacent the second side surface such that the first bridge is disposed between the recess of the front edge and the hole. It is contemplated that each masonry unit may further include a channel extending longitudinally along the base from the recess of the front edge to the hole and extends transversely through the first bridge. 
     In embodiments, the plurality of first reinforcing bars and the at least one second reinforcing bar may be perpendicular to one another. The cage may include a plurality of box-like straps that surrounds the plurality of first reinforcing bars. The cage may include a plurality of hooks connecting each first reinforcing bar of the plurality of first reinforcing bars to the straps. 
     It is contemplated that the masonry structure may further include a plurality of stacked rows of cinder blocks forming at least one wall. The plurality of masonry units cap the at least one wall such that the enclosed passageway of each pair of adjacent masonry units may be in coaxial alignment with holes of the cinder blocks. 
     In some aspects, the recesses of each masonry unit may have a semi-circular profile. 
     In further embodiments, a first bridge of the pair of spaced apart bridges of each masonry unit may be adjacent a first recess of the recesses of each masonry unit and a second bridge of the pair of spaced apart bridges of each masonry unit may be adjacent a second recess of the recesses of each masonry unit. The first recess of each masonry unit may occupy an entire area defined between the sidewalls, the first bridge, and the front edge of each masonry unit. The second recess of each masonry unit may occupy an entire area defined between the sidewalls, the second bridge, and the rear edge of each masonry unit. 
     It is envisioned that the bridges of each masonry unit may have an upper surface that defines a pair of spaced apart grooves each configured for disposal of one of the plurality of first reinforcing bars. The spaced apart grooves of the bridges of each masonry unit may have a semi-circular configuration. In embodiments, the upper surface of each bridge may be spaced from the base to define a height of each bridge. 
     In yet another aspect of an embodiment of the present disclosure, a concrete building block for constructing built structures is provided. The concrete building block includes a rectangular shaped base having a front edge and a rear edge. The front edge and the rear edge each include a recess formed therein configured for disposal of a vertically disposed reinforcing bar. Each recess has a semi-circular profile. The concrete building block further includes a pair of spaced apart sidewalls extending perpendicularly from the base and along a length of the base. The sidewalls and the base together define a cavity configured for disposal of a fill material. The concrete building block further includes a pair of spaced apart trapezoidal-shaped bridges supported on the base and configured for disposal of lengths of horizontally disposed reinforcing bars. The bridges extend transversely between the sidewalls and each have a height less than a height of the sidewalls. Each bridge has an upper surface that is spaced from the base to define a height of each bridge. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       In order that the present disclosure may be clearly understood, preferred embodiments thereof will be described below with reference to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of a building block according to an embodiment of the present disclosure; 
         FIG. 2  is a top, plan view of the building block of  FIG. 1 ; 
         FIG. 3  is a front, elevational view of the building block of  FIGS. 1 and 2 ; 
         FIG. 4  is a cross-sectional view of the building block of  FIGS. 1-3 , as taken through  4 - 4  of  FIGS. 2 and 3 ; 
         FIG. 5  is an enlarged view of the indicated area of detail of  FIG. 3 , illustrating and end of building block according to another embodiment of the present disclosure; 
         FIG. 6  is a first perspective view of a partial construction of a wall or structure including a plurality of building blocks of  FIGS. 1-5 ; 
         FIG. 7  is a second perspective view of the partial construction of the wall or structure of  FIG. 6 ; 
         FIG. 8  is a perspective view of a partial wall construction, constructed in accordance with the building blocks and methods of the present disclosure; 
         FIG. 9  is a top, plan view of another embodiment of a building block in accordance with the principles of the present disclosure; and 
         FIG. 10  is a front, perspective view of the building block shown in  FIG. 9 . 
     
    
    
     As used herein, the terms parallel and perpendicular are understood to include relative configurations that are substantially parallel and substantially perpendicular up to about + or −10 degrees from true parallel and true perpendicular. 
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Referring to the drawings and initially to  FIGS. 1-4  there is shown a full masonry unit, such as, for example, a building block, in accordance with an embodiment of the present disclosure, and is generally designated as building block  100 . 
     As seen in  FIGS. 1-4 , building block  100  includes a base  102  defining a pair of opposed, parallel side edges  104 ,  106 , a front edge  108  and a rear edge  110 . Base  102  of building block  100  is substantially rectangular having a length “L” (e.g., about 15½ inches) and a width “W” (e.g., about 7½ inches). 
     Building block  100  includes a pair of spaced apart side walls  112 ,  114  extending from respective side edges  104 ,  106  of base  102 . Each side wall  112 ,  114  has a height “H” (e.g., e.g., about 7½ inches) and terminates in an upper edge or surface  112   a ,  114   a . Each wall  112 ,  114  extends substantially orthogonally from base  102 . Each wall  112 ,  114  includes a respective inner surface  112   b ,  114   b , wherein inner surfaces  112   b ,  114   b  are angles with respect to base  102  so as to extend towards one another from respective upper surfaces  112   a ,  114   a  toward base  102 . In other words, each wall  112 ,  114  includes a respective outer surface  112   c ,  114   c  extending substantially orthogonally to base  102  and being substantially parallel to one another, and respective inner surfaces  112   b ,  114   b  that are angled with respect to respective outer surfaces  112   c ,  114   c  and which extend toward one another from respective upper surfaces  112   a ,  114   a  toward base  102 . As so configured, a channel or cavity  120  is defined within building block  100 . 
     With continued reference to  FIGS. 1-4 , building block  100  includes at least a first bridge  126  supported on or extending from base  102  and extending transversely between inner surface  112   b  of side wall  112  and inner surface  114   b  of side wall  114 , and a second bridge  128  supported on or extending from base  102  and extending transversely between inner surface  112   b  of side wall  112  and inner surface  114   b  of side wall  114 . Bridges  126 ,  128  may have a trapezoidal shape. In some embodiments, bridges  126 ,  128  can be variously configured, such as, for example, concave, undulating, scalloped, squared, uniform, non-uniform and/or tapered. Each bridge  126 ,  128  defines a respective upper edge or surface  126   a ,  128   a  having a height “h” above base  102 . Height “h” of bridges  126 ,  128  is less than height “H” of building block  100 , wherein upper surfaces  126   a ,  128   a  of bridges  126 ,  128  are disposed below upper surfaces  112   a ,  114   a  of side walls  112 ,  114 . For example, bridges  126 ,  128  may have a height “h” of about 1-4 inches above an upper surface of base  102 . 
     As seen in  FIGS. 2 and 4 , bridges  126 ,  128  are spaced a distance “d” from respective front edge  108  and rear edge  110  of base  102 . For example, bridges  126 ,  128  may be spaced a distance “d” of about 1-4 inches from respective front edge  108  and rear edge  110  of base  102 . 
     In accordance with the present disclosure, each of bridges  126 ,  128  may include a pair of spaced apart grooves  127   a ,  127   b  (shown in phantom in  FIGS. 2 and 5 ) defined in upper surfaces  126   a ,  128   a , respectively. Grooves  127   a ,  127   b  are configured for disposal of reinforcing material “R 1 .” Grooves  127   a ,  127   b  may have a semi-circular configuration such that reinforcing material “R 1 ” can be slidingly disposed in grooves  127   a ,  127   b.    
     As so configured, bridges  126 ,  128  may support lengths of first reinforcing material “R 1 ” (e.g., bars, rebar, pipes, tubes, etc.) thereon, in a horizontal orientation, wherein first reinforcing material or bars “R 1 ” are located within channel or cavity  120  of building block  100  between side walls  112 ,  114 . In this manner, first reinforcing bars “R 1 ” are raised above a top surface  302   a  of base  102  when first reinforcing bars “R 1 ” are located or disposed within channel or cavity  120 . 
     While a pair of bridges  126 ,  128  are shown and provided, in accordance with the present disclosure, additional bridges (shown in phantom in  FIGS. 2 and 4 ) may be provided between bridges  126 ,  128 . 
     With reference to  FIGS. 1-4 , building block  100  includes a cut-out or recess  122   a ,  122   b  formed in each of respective front edge  108  and rear edge  110  of base  102 . In particular, each recess  122   a ,  122   b  is located between side walls  112  and  114 , and extends completely through base  102 . In embodiments, recesses  122   a ,  122   b  may extend into respective front edge  108  and rear edge  110  of base  102  up to respective bridges  126 ,  128 . Each recess  122   a ,  122   b  may have a substantially semi-circular profile or footprint. While building block  100  is shown and described as including a cut-out or recess  122   a ,  122   b  formed in each side of base  102 , it is contemplated and envisioned that building block  100  may include only one cut-out or recess formed in one edge of base  102 , either front edge  108  or rear edge  110 . 
     In an embodiment, as seen in  FIG. 5 , recesses  122   a ,  122   b  may constitute the entire area defined between side walls  112 ,  114 , respective bridges  126 ,  128 , and respective front edge  108  or rear edge  110 . 
     In use, when building blocks  100  are placed adjacent to one another such that a front edge  108  of a first building block  100  abuts or is adjacent a second edge  110  of a second building block  100 , recess  122   a  of first building block  100  is adjacent recess  122   b  of second building block. In this manner, as seen in  FIGS. 1-4 , lengths of second reinforcing material “R 2 ” (e.g., bars, rebar, pipes, tubes, etc.) may be disposed within combined recess  122   a / 122   b , in a vertical orientation, wherein second reinforcing bar “R 2 ” is located between adjacent building blocks  100 . 
     As seen in  FIGS. 3-7 , a plurality of reinforcing bars “R 1 ” are arranged in parallel to one another in the configuration of a box or cage “C”, with a plurality of rigid square or box-like belts or straps “S” surrounding the plurality of reinforcing bars “R 1 ” making up cage “C”, and with a tie of hook “T” connecting each reinforcing bar “R 1 ” to a respective inner corner of strap “S”. With cage “C” formed in this manner, cage “C” is placed in cavity  120  of building blocks  100  such that a first pair of reinforcing bars “R 1 ” are disposed atop bridges  126 ,  128 , and a second pair of reinforcing bars “R 1 ” are disposed a distance upwardly from bridges  126 ,  128 . 
     With reference now to  FIGS. 6 and 7 , when constructing a masonry structure “St” (i.e., wall or the like) with building blocks  100 , a plurality of cages “C” may be laid, in a horizontal orientation, into cavities  120  of building blocks  100 , along at least a portion, preferably an entire length, of the structure “St”. If cages “C” extend completely around a perimeter of the structure “St”, cages “C” may substantially define a belt or the like around the structure “St”. It is contemplated that instead of using a plurality of cages “C,” one cage “C” can be used. In some embodiments, one cage “C” can be bent to form a belt or the like and disposed into cavities  120  of building blocks  100 . 
     Also, when constructing the structure ‘St” with building blocks  100 , multiple second reinforcing materials “R 2 ” may be inserted, in a vertical orientation, into combined recess or enclosed passageway  122   a / 122   b  between adjacent building blocks  100 , all along at least a portion, preferably an entire height, of the structure “St”. In use, if second reinforcing materials “R 2 ” are used in combination with cages “C”, cages “C” and second reinforcing materials “R 2 ” may substantially define an overall cage structure or the like for structure “St”. 
     In use, following a laying of each row of building blocks  100 , and a placement of cages “C” in the cavities  120  thereof, the cavities  120  may be filled with fill material “F”, including and not limited to uncured flowable concrete, sand, gravel, dirt, stone, crushed concrete or the like, and any combinations thereof. Since cages “C” are supported on bridges  126 ,  128 , the uncured flowable concrete may completely surround and envelope first reinforcing materials “R 1 ” of cages “C”. 
     Due to the relative dimensions and sizes of reinforcing materials “R 1 ”, “R 2 ” and cages “C”, lengths of bridges  126 ,  128 , and widths of recesses  122   a ,  122   b , in accordance with the present disclosure, it is contemplated that reinforcing materials “R 1 ”, “R 2 ” and cages “C” may be positioned any where along the length of bridges  126 ,  128 , or the width of recesses  122   a ,  122   b . It is further contemplated that multiple reinforcing materials “R 1 ”, “R 2 ” may be used at desired or needed locations of structure “St”. 
     Turning now to  FIG. 8 , in a construction or structure “St”, a plurality of rows of cinder blocks  200  are stacked in accordance with known construction techniques to create at least one wall (here, a pair of walls “W 1 ,” “W 2 ”). In accordance with the present disclosure, a row of building blocks  100  are disposed atop walls “W 1 ,” “W 2 ” to cap walls “W 1 ,” “W 2 ”. In accordance with the present disclosure, recess  122   a /( 122   b  not shown) of building blocks  100  align with the holes or passages  202  of under lying cinder blocks  200 . As so arranged, reinforcing material “R 2 ” (i.e., rebar) in inserted into walls “W 1 , W 2 ” so as to extend through recess  122   a /( 122   b  not shown) of building blocks  100  and holes or passages  202  of under lying cinder blocks  200 . Additionally, fill material “F” may be used to fill cavities  120  of the upper row of building blocks  100 , as well as to flow down into recess  122   a /( 122   b  not shown) of building blocks  100  and holes or passages  202  of under lying cinder blocks  200 . 
     The use of rebar “R 2 ” and fill material “F” in a vertical column adds strength and rigidity to the walls “W 1 , W 2 ” of structure “St”. 
     In accordance with the present disclosure, it is contemplated that any row of cinder blocks  200  of structure “St” may be replaced with a row of building blocks  100  of the present disclosure. Additionally, it is envisioned and contemplated that each row of building blocks  100  may include a cage “C” supported therein and then the respective cavity  120  filled with fill material “F”. 
     With reference to  FIGS. 9 and 10 , there is shown another embodiment of a full masonry unit, such as, for example, a building block, similar to building block  100  discussed above with regard to  FIGS. 1-8 , and is generally designated as building block  300 . Building block  300  includes a base  302  defining a pair of opposed, parallel side edges  304 ,  306 , a front edge  308 , and a rear edge  310 . 
     Building block  300  includes a pair of spaced apart side walls  312 ,  314  extending from respective side edges  304 ,  306  of base  302 . Each side wall  312 ,  314  has a height “H” (e.g., e.g., about 7½ inches) (See  FIG. 10 ) and terminates in an upper edge or surface  312   a ,  314   a . Each wall  312 ,  314  extends substantially orthogonally from base  302 . Each wall  312 ,  314  includes a respective inner surface  312   b ,  314   b , wherein inner surfaces  312   b ,  314   b  are angled with respect to base  302  so as to extend towards one another from respective upper surfaces  312   a ,  314   a  toward base  302 . In other words, each wall  312 ,  314  includes a respective outer surface  312   c ,  314   c  extending substantially orthogonally to base  302  and being substantially parallel to one another, and respective inner surfaces  312   b ,  314   b  that are angled with respect to respective outer surfaces  312   c ,  314   c  and which extend toward one another from respective upper surfaces  312   a ,  314   a  toward base  302 . As so configured, a channel or cavity  320  is defined within building block  300 . 
     Building block  300  includes at least a first bridge  326  supported on or extending from base  302  and extending transversely between inner surface  312   b  of side wall  312  and inner surface  314   b  of side wall  314 , and a second bridge  328  supported on or extending from base  302  and extending transversely between inner surface  312   b  of side wall  312  and inner surface  314   b  of side wall  314 . Bridges  326 ,  328  may have a trapezoidal shape. Each bridge  326 ,  328  defines a respective upper edge or surface  326   a ,  328   a  spaced from top surface  302   a  of base  302  to define a height “h” above base  302  (See  FIG. 10 ). Height “h” of bridges  326 ,  328  is less than height “H” of building block  300 , wherein upper surfaces  326   a ,  328   a  of bridges  326 ,  328  are disposed below upper surfaces  312   a ,  314   a  of side walls  312 ,  314 . For example, bridges  326 ,  328  may have a height “h” of about 1-4 inches above an upper surface of base  302 . Bridges  326 ,  328  are spaced a distance “d” from respective front edge  308  and rear edge  310  of base  302 . For example, bridges  326 ,  328  may be spaced a distance “d” of about 6-7 inches from respective front edge  308  and rear edge  310  of base  302 . 
     First bridge  326  further includes a first side surface or face  332   a  and a second side surface or face  332   b , opposite first side surface  332   a . First side surface  332   a  is oriented towards front edge  308  of base  302  and second side surface  332   b  is oriented away from front edge  308  of base  302  and towards rear edge  310  of base  302 . 
     Building block  300  includes a cut-out or recess  322   a ,  322   b  formed in each of respective front edge  308  and rear edge  310  of base  302 . In particular, each recess  322   a ,  322   b  is located between side walls  312  and  314 , and extends completely through base  302 . Recess  322   a  of front edge  308  is disposed adjacent first side surface  332   a  of first bridge  326 . In embodiments, recesses  322   a ,  322   b  may extend into respective front edge  308  and rear edge  310  of base  302  up to respective bridges  326 ,  328 . Each recess  322   a ,  322   b  may have a substantially semi-circular profile or footprint. 
     Building block  300  includes a channel or passageway  334  extending longitudinally along base  302  from recess  322   a  and transversely through bridge  326 . Passageway  334  has a linear configuration and has a height extending from a bottom surface  302   b  of base  302  to upper surface  326   a  of bridge  326  such that bridge  326  is divided into two, spaced apart portions by passageway  334 . In embodiments, passageway  334  may only extend from upper surface  326   a  of bridge  326  to top surface  302   a  of base  302  and not through the entire thickness of base  302 . 
     Building block  300  further includes an opening or hole  336  defined through the thickness of base  302 . Hole  336  has a rounded configuration and a diameter of approximately 3 inches. It is contemplated that hole  336  is variously configured, such as, for example, those alternatives described herein, and may be approximately 2-4 inches in diameter. Hole  336  is disposed adjacent second side surface  332   b  of first bridge  326  such that first bridge  326  is disposed between recess  322   a  of front edge  308  and hole  336 . Hole  326  is in communication with recess  322   a  via passageway  334 . Hole  336  is configured for disposal of a vertically oriented support member, such as, for example, rebar. In embodiments, building block  300  may include an additional passageway and hole that are disposed adjacent rear surface  310 . 
     In accordance with the present disclosure, and without limiting the present application, building blocks  100 ,  300  may be fabricated from any curable, castable and/or moldable cementitious material, such as, for example, concrete, cement, cement/polymer mixtures, concrete mixed with polystyrene, recycles concrete (RCA), crushed concrete, wood, clay, ceramics, aluminum, steel, rubber, etc. and combinations thereof. 
     Consideration must be given to the fact that although present disclosure has been shown, described, and disclosed in relation to certain preferred embodiments, obvious equivalent modifications and alterations thereof will become apparent to one of ordinary skill in this art upon reading and understanding this specification and the claims appended hereto. Accordingly, the presently disclosed invention is intended to cover all such modifications and alterations, and is limited only by the scope of the claims which follow.