Patent Publication Number: US-7587870-B2

Title: Grid system for mounting building blocks

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims the benefit of provisional application Ser. No. 60/775,166, entitled “A Grid System for Mounting Building Blocks,” which was filed on Feb. 21, 2006, the disclosure of which is incorporated herein by reference. 

   FIELD OF THE INVENTION 
   The present invention relates to grid systems for building walls or other structures utilizing building blocks, most commonly glass blocks. 
   BACKGROUND OF THE INVENTION 
   Grid systems designed to hold building blocks in a spaced relationship are well known. Most commonly, these are intended as an alternative to laying the blocks (typically glass or masonry) in mortar. The existing grid systems tend to use components of thin dimensions and of relatively weak construction. Furthermore, the existing systems have relatively weak connections between the horizontal and vertical framing members and, in some cases, no connections at all. In addition, existing systems typically depend on a sealant material, such as silicone or urethane, to seal the blocks against water infiltration at their perimeters. 
   Furthermore, most existing grid systems which are intended for use with glass blocks incorporate portions of the linear framing members which engage the center ridges which exist around the perimeters of the edges of common glass blocks. This feature helps to stabilize the blocks but prevents the use of those particular blocks that do not have the perimeter recesses and ridge features common to most glass blocks. Also, many of the existing grid systems do not include cavities that are continuous in either the longitudinal or transverse directions in such a way that they can act as a conduit for strip lighting, wiring, liquid carrying hoses, or other such elements. 
   Still further, existing grid systems typically rely on using the block elements to act as gauges to determine the spacing between the (short) vertical framing members. This can result in a grid system which is not precisely aligned owing to variations in the sizes of the blocks or foreign objects that may be lodged between the blocks and the framing members. Existing systems typically rely on a sealant material, such as silicone or urethane, as the exposed joint material and as the means of preventing water from entering the wall system. The use of such sealant materials does not typically provide a consistent appearance and typically requires periodic replacement due to wear caused by age or weathering. 
   Should water pass through the outer portions of the joints, existing grid systems do not have a provision for directing the leakage water to the bottom of the wall and then exhausting same to a desired location. Existing grid systems are also not built with the option for accepting rectilinear blocks which have flat, square edges and alternatively, common glass blocks which have recessed ridges around their perimeter edges. Finally, existing grid systems do not typically include a provision for the entire system to expand and contract at the sides and tops of a given wall opening. This can be a major factor, in particular in the case of framing members that are made of thermoplastics or other materials that have a high thermal expansion coefficient and in the case where large walls are constructed. Thus, there is a need for a block mounting system that addresses one or more of the above-described problems associated with existing grid systems. 
   SUMMARY OF THE INVENTION 
   The present invention, in one or more embodiments, provides an assembly of horizontal and vertical framing members which, when assembled, creates a grid. The grid forms discrete openings into which building blocks are placed as the grid is assembled. During the assembly process, clips are fitted through holes in the horizontal framing members. Lower portions of the clips engage vertical framing members beneath and upper portions of the clips engage vertical framing members above. The outside edges of the vertical and horizontal framing members are exposed to view and offer many optional colors and joint treatments. In addition, provision is made for accepting thermal expansion and contraction of the framing members. Optionally, elements can be housed within the horizontal framing members to provide increased strength or other features such as conduits for lighting, power, or fluid. The entire system can be assembled very quickly by relatively unskilled personnel. 
   In one embodiment, the present invention provides a block assembly that includes a plurality of first framing members, a plurality of second framing members, and a plurality of clips, wherein each of the clips is inserted through a respective one of the first framing members. In addition, each of the clips has an upper portion that extends above an upper surface of the first framing member through which it is inserted and a lower portion that extends below a lower surface of the first framing member through which it is inserted. For each of the clips, the upper portion is received within a first one of the second framing members and the lower portion is received within a second one of the second framing members such that the clips interconnect the first and second framing members to form a grid including a plurality of openings. The block assembly further includes a plurality of blocks, such as glass, plastic or masonry blocks, with each of the blocks being received within a respective one of the openings. 
   The lower portion of each of the clips may include a plurality of legs which are inserted through holes provided in the first framing members. Also, for each of the clips, the upper portion may be received within a cavity provided within a first one of the second framing members and the lower portion may received within a cavity provided within a second one of the second framing members. 
   In addition, for each of the blocks, a sealant may be provided between the block and the first framing members between which the block is located. Alternatively, for each of the blocks, one or more elastomeric members may be provided between the block and the first framing members between which the block is located. 
   In one particular embodiment, each of the first framing members may also include a central cavity, wherein a reinforcing element is received within the central cavity. Alternatively, one or more of a hose, a wire or a lighting element may be provided within the central cavity of one or more of the first framing members. In another particular embodiment, each of first framing members includes a first outer flange and a second outer flange opposite the first outer flange, and an elastomeric strip is attached to each of the first outer flanges and each of the second outer flanges. Finally, the block assembly may further includes an angle clip for moveably attaching the block assembly to a wall, wherein a first portion of the angle clip is affixed to the wall and wherein a second portion of the angle clip is slideably received within a cavity provided within one of the first framing members. 
   Therefore, it should now be apparent that the invention substantially achieves all the above aspects and advantages. Additional aspects and advantages of the invention will be set forth in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. Moreover, the aspects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description given below, serve to explain the principles of the invention. As shown throughout the drawings, like reference numerals designate like or corresponding parts. 
       FIG. 1  is an exploded view of a block assembly according to an embodiment of the present invention; 
       FIG. 2  is a cross-section through a horizontal framing member or a vertical framing member employed in the assembly of  FIG. 1 ; 
       FIG. 3  is a side sectional view which illustrates a typical horizontal framing member which is positioned between two building blocks; 
       FIG. 3A  is a side sectional view a portion of a horizontal framing member or a vertical framing member employed in the assembly of  FIG. 1  that includes optional elastomeric sealing cushions according to one particular embodiment of the invention; 
       FIG. 3B  is a side sectional view a portion of a horizontal framing member or a vertical framing member employed in the assembly of  FIG. 1  wherein the outer flanges thereof are covered by continuous elastomeric strips according to another particular embodiment of the invention; and 
       FIG. 4  is an isometric view of a typical horseshoe clip employed in the assembly of  FIG. 1 . 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1  is an exploded view of an array of blocks  1 , which are typically made of masonry, plastic, or glass (although other suitable materials may also be used) and which are assembled within a grid framework composed of horizontal framing members  2  and vertical framing members  3 , all of which are held together by horseshoe clips  4 . Framing members  2  and  3  and clips  4  are typically made of aluminum or of plastics such as PVC or FRP, although other suitable materials may also be used. The described array of blocks  1  and grid framing formed by the framing members  2  and  3  typically forms a wall, which then typically fills a substrate opening  15 . The horizontal framing members  2  are secured to the jamb surfaces of the substrate  15  via angle clips  5 , the clips being secured to the jamb wall via anchors  6 , which may be screws, nails, or masonry anchors, among other suitable fasteners. The horizontal portion  16  of each clip  5  is slidably engaged in the cavity  12  of the associated horizontal framing member  2  so as to allow for expansion and contraction of the horizontal framing member  2 . The vertical framing members  3  are secured to the horizontal framing members  2  via the horseshoe clips  4 . As can be seen in  FIG. 1 , the horizontal portion  16 , or second portion, is generally T-shaped such that its outer end  16   b  has a width greater than its inner end  16   a . In this manner, inner end  16   a  is of a width which allows each clip  4  to penetrate aligned holes  24  defined on each first framing member while the angle clip  5  is simultaneously maintained within the cavity  12 . As seen in  FIG. 1 , the downward extending legs  13  of the clips  4  pass through holes  24  that are provided in the horizontal framing members  2  and then pass into the channel openings  12  of the underlying vertical framing member  3 . Another (overlying) vertical framing member  3  then slides over the upper surface  14  of the clip  4  thus connecting the vertical framing member  3  to the horizontal framing member  2 . The holes are preferably precisely spaced so as to consistently determine the distance between vertical framing members  3 . As the grid system is built, the building blocks  1  are progressively inserted into the discrete openings that are created by the grid system. 
     FIG. 2  is a cross-section through a horizontal framing member  2  or a vertical framing member  3 . These members are composed of two outer flanges  8 , which are connected to central web portions  7  which, in turn, are connected to an elongated channel portion composed of a web  10  and flange portions  11  which, when spaced apart from web  10 , create cavities  12  at each end of the channel. 
     FIG. 3  illustrates a typical horizontal framing member  2 , which is positioned between two building blocks  1 . Shown with dotted lines is a typical clip  4 , which passes through the holes  24  provided in the horizontal framing member  2  and which includes downwardly extending legs  13  and an upwardly extending body portion  14 . 
   A sealant/adhesive  17  is shown in one preferred embodiment as a means of sealing the joints between the horizontal framing members  2  and the building blocks  1  as well as being a means for adhering and permanently joining the horizontal framing members  2  and the building blocks  1 . In a preferred embodiment, a sealant  25  may be installed as an exterior joint seal. In one particular embodiment, a steel reinforcement member  23  is provided within the cavity  18  of the horizontal framing member  2  as a means for adding strength to the horizontal framing member  2 . 
     FIG. 3A  illustrates a portion of the horizontal framing member  2  (and the vertical framing member  3 ) and includes optional elastomeric sealing cushions  19  engaged in the cavities  9  of the horizontal framing members  2  (or the vertical framing members  3  as the case may be). These elastomeric sealing cushions  19  may be composed of elastomeric materials such as EPDM or neoprene and serve to seal the joints between the building blocks  1  and the framing members  2  or  3 . Also illustrated is a hose, wiring or lighting element  20  which, as an option, may be placed within the cavities  18  of the horizontal framing members  2  in order to convey electrical power, liquids, and/or lighting elements. 
     FIG. 3B  shows another preferred embodiment wherein the outer flanges  8  of the horizontal framing members  2  and/or the vertical framing members  3  are covered by continuous elastomeric strips  21 . Preferably, the strips  21  are formed as channels with barbs  22  which cause the elastomeric strips  21  to be secured to the flanges  8 . Being an elastomeric material, such as EPDM or neoprene, the strips  21  provide sealing of the joints between the building blocks  1  and the framing members  2  and  3  and also provide support where building blocks  1  rest upon them. 
     FIG. 4  is an isometric drawing of a typical horseshoe clip  4 , which has been previously described. The clips  4  may be made of thermoplastic, FRP aluminum, steel, or any other suitable material. The downward legs  13  are of a dimension which allows the legs  13  to fit through the holes  24  provided in the horizontal framing members  2  as illustrated in  FIG. 1 . As can be seen, legs  13  are co-planar to upper body portion  14 . The holes  24  are nominally a quarter inch in diameter and the downward legs  13  of the clip  4  are sized to allow for an appropriate clearance, typically on the order of 0.010 inches. Also, the downward legs  13  have a thickness that is designed to fit inside cavity  12  of the vertical framing members  3  with an appropriate clearance, typically on the order of 0.010 inches. The horseshoe clip  4  also has an upper body portion  14 , the thickness of which is designed to fit into the cavities  12  of the vertical framing members  3  with an appropriate clearance, typically on the order of 0.010 inches. The engagement of the legs  13  and the upper body portions  14  of the clips  4  as just described secure the vertical framing members  3  to the horizontal framing members  2 . 
   While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present invention. Accordingly, the invention is not to be considered as limited by the foregoing description but is only limited by the scope of the appended claims.