Patent Publication Number: US-9410313-B1

Title: Building block system

Description:
This patent application is a divisional application from U.S. application Ser. No. 12/974,232, filed Dec. 21, 2010, which is a non-provisional application that claims priority to U.S. provisional application Ser. No. 61/289,002, filed on Dec. 22, 2009 and incorporates the same by reference as if set forth herein in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention generally relates to a building block design for use in a building block system, and more particularly, an interlocking block system incorporating interlocking building blocks, joist hangers, roof truss anchors, and thermal encapsulation members disposed on the external face of the block. The inventive building block allows for the construction of an interlocked wall and transverse wall using a plurality of blocks that all having the same design. 
     2. Discussion of Related Prior Art 
     Traditional building block structures are constructed masonry style with layers (or courses) of overlapping blocks fixed together with mortar mix between blocks and between courses. Traditional mortar-less block applications attempt to address this issue. 
     Osbourne, U.S. Pat. No. 4,651,485 discloses an interlocking building block system having a plurality of building blocks having ribs on some faces and recesses on other faces to receive ribs of another of the block. The blocks are stacked next to each other to form a course, and the second course is staggered above the first course such that the vertical joints of the first course do not line up with the vertical joints of an adjoining course of block. A corner block is necessary with this system to provide for a complete system. Accordingly, a transverse wall of interlocking block cannot be constructed without the additional corner block design. 
     The prior art discussed by Osbourne also addresses other mortar-less block applications. The prior art in general and the art discussed do not disclose the inventive building block system disclosed herein. 
     SUMMARY OF THE INVENTION 
     The present invention may be embodied as mortar-less building block for building a structure. The block designed to implement a complete system utilizing a single building block configurably adapted to be utilized in building corners of structures, transverse courses, and additional courses above the first course. The building block having a front face and a back face, a top face and a bottom face, and a protrusion side face and a recess side face all connected to form the building block. The front face and the back face each having a pair of longitudinal recesses preferably spaced apart by 8 inches. The top face having a pair of longitudinal recesses aligned with the longitudinal recesses of the front face and the back face, and the top face further having a transverse recess centrally located on the top face transversely intersecting the pair of longitudinal recesses, creating intersection points. The recess side face having a transverse recess aligned with the transverse recess of the top face. The protrusion side face having a transverse protrusion designed to mate with the transverse recess of an other of the building block. The recess side face and the protrusion side face (the side faces) are designed to interlock with other blocks to provide enhanced resistance to forces normal to the wall face. The bottom face having at least one transverse protrusion for mating with the recess of a top face of an other of the building block. The transverse protrusion of the bottom face is aligned with the recess of the recess side face, and aligned with the protrusion of the protrusion side face. 
     In a preferred embodiment, the mortar-less building block has a pair of bores, each bore longitudinally disposed to extend from the intersection points of the top face to corresponding bottom face intersection points, thereby allowing a user to place a rod within the bore of a first building block and within the bore of a second building block when said first and second building blocks are placed on top of each other. 
     The present invention includes a plurality of joist hangers for supporting a joist, each joist hanger having an upper anchoring member attached to an upper u-shaped channel, a lower anchoring member attached to a lower u-shaped channel, and one or more connective members connecting the upper u-shaped channel to the lower u-shaped channel, so to receive a joist within said upper and lower u-shaped channels. The upper and lower anchoring members having mounts for alignment with a bore of the pair of bores of the block and for receiving an anchor such as a rod or a bolt. 
     The present invention includes a plurality of truss brackets for anchoring a portion of a truss onto the block, each truss bracket having a recess shaped channel and a pair of arms for receiving the portion of the truss and a bore mount for anchoring the recess channel to a bore of the block with an anchor such as a rod or a bolt. The recess channel further includes a plurality of mounts for receiving a fastener such a screw or a nail for fixing the portion of the truss to the recess channel when the portion of the truss is disposed within the recess channel. 
     The present invention further includes a half-block for cooperating with the building block to construct openings such as doorways and windows into a wall. The half block having a front face and a back face, a top face and a bottom face, and a protrusion side face and a recess side face all connected to form the building block. The front face and the back face each having a longitudinal recess. The top face having a longitudinal recess aligned with the longitudinal recess of the front face and the back face, and the top face further having a transverse recess centrally located on the top face transversely intersecting the longitudinal recess, creating an intersection point. The recess side face having a transverse recess aligned with the transverse recess of the top face. The protrusion side face having a transverse protrusion designed to mate with the transverse recess of an other of the building block. The bottom face having at least one transverse protrusion for mating with the top face of an other of the building block, the transverse protrusion aligned with the transverse recess of the recess side face, and aligned with the transverse protrusion of the protrusion side face. The half block further having a bore extending through the half block in a direction normal to the top face to enable a rod to be placed through the bore of the half block and into the bore of another block. 
     The present invention may be embodied as mortar-less building block system for building a structure. The system comprising the mortar-less building block as described herein, a plurality of alignment rods, a plurality of joist hangers, and a plurality of truss brackets, and an insulating member disposed exterior to the mortar-less building block. 
     The present invention may be embodied as a thermal reservoir structural wall comprising one or more of the components of the system described herein and further comprising an insulating member applied to the exterior facing face of the block(s). 
     The present invention includes a method of constructing a block wall comprising placing a first block in a first location; forming a course by mating one side face of the first block with a cooperating side face of an additional block, laterally interlocking one or more additional blocks by mating one side face of the one or more additional blocks with a cooperating side face of an other of the one or more additional blocks or the additional block; forming a transverse course by mating one recess of the front or back face of the first block with a protrusion side face of an additional block, laterally interlocking one or more additional blocks by mating one side face of the One or more additional blocks with a cooperating side face of an other of the one or more additional blocks or the additional block; laying an additional course by mating the transverse protrusion of the bottom face of an additional block with either a transverse recess or a longitudinal recess of the first block or one or more additional blocks, and aligning the bore of the additional block with the bore of the first block or the one or more additional blocks; inserting a rod or alignment pin into a bore of one block and extending the rod or alignment pin into a bore of one or more additional blocks. 
     OBJECTS OF THE INVENTION 
     It is an object of the present invention to present a concept in building design and construction by using a mortar-less, self-aligning, interlocking building block that may be assembled in longitudinal staggered rows or courses to form a solid and sturdy wall structure. The blocks by the use of pins inserted through bores of the blocks, may be dry stacked or sealed with a cement-like bonding sealer on all joints. 
     It is another object of the present invention to provide an extreme wind resistance building system. 
     It is another object of the present invention to provide an earthquake resistant building. 
     It is another object of the present invention to provide a fire resistant building structure. 
     It is another object of the present invention to provide a termite resistant building structure. 
     It is another object of the present invention to provide interlocking building wall corners, where no corner blocks are needed, regular blocks are used on corners, to provide uniform configuration and simplicity in building block components. 
     It is another object of the present invention to provide a uniform interlocking building block having vertical center holes every 8 inches on center for aligning pins and rebar for building codes. 
     It is another object of the present invention to provide a wall structure of interlocking blocks having a vertical rectangular-trapezoidal channels interior and exterior which may be used for plumbing, electrical wires, conduit, air ducts or inserting 2.times.4 building lumber for structural members. 
     It is another object of the present invention to provide thermodynamic heat storing interior wall system by using a rigid or liquid spray foam insulation on the exterior of the wall. 
     It is another object of the present invention to provide a continuous vertical wall system from foundation footers to roof truss by fastening floor joists on interior walls with specially adapted joist angers and roof truss anchors. 
     It is another object of the present invention to provide horizontal rectangular-trapezoidal channels for roof truss anchors spaced every 8 inches on center on top tow or course of blocks by the use of special truss hanger brackets secured in channels for a stronger wind resistance structural fastening roof truss system. 
     It is another object of the present invention to provide a wall structure building block system that would reduce structural damage in a flooding/high water situation. 
     It is another object of the present invention to provide blocks that are of a relatively simply uniform configuration, and walls constructed of said blocks. 
     It is another object of the present invention to provide a structural building block system that would reduce time and construction cost. 
     Accordingly, it is an object of the present invention to provide a structural block system that overcomes the drawbacks of the prior art, and other objects will become apparent in the detailed description and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The advantages, nature and various additional features of the invention will appear more fully upon consideration of the illustrative embodiment of the invention which is schematically set forth in the drawings, in which: 
         FIG. 1  is a front view of one embodiment of a channel block. 
         FIG. 2  is a top view of the channel block of  FIG. 1 . 
         FIG. 3  is a bottom view of the channel block of  FIG. 1 . 
         FIG. 4  is a left hand end view of the channel block of  FIG. 1  and a half block. 
         FIG. 5  is a right hand end view of the channel block of  FIG. 1  and a half block. 
         FIG. 6  is a front view of the half block. 
         FIG. 7  is a top view of the half block. 
         FIG. 8  is a bottom view of the half block. 
         FIG. 9  is a front view of the joist hanger. 
         FIG. 10  is an end view of the joist hanger. 
         FIG. 11  is a top view of the joist hanger. 
         FIG. 12  is a bottom view of the joist hanger. 
         FIG. 13  is a front view of the truss bracket. 
         FIG. 14  is a side view of the truss bracket. 
         FIG. 15  is a plan view of two channel blocks. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     While the invention is open to various modifications and alternative forms, specific embodiments thereof are shown by way of examples in the drawings and are described herein in detail. There is no intent to limit the invention to the particular forms disclosed. 
     Referring now to the drawings, in particular to  FIGS. 1-5 , the present invention is a mortar-less building block  11  for building a structure. The building block  11  having a front face  13  and a back face  15 , a top face  17  and a bottom face  19 , and a protrusion side face  21  and a recess side face  23  all connected to form the building block  11 . 
     Referring to  FIGS. 1-2 , the front face  13  and the back face  15  each have a pair of longitudinal recesses  25  that preferably are spaced apart by 8 inches. 
     Referring to  FIG. 2 , the top face  17  has a pair of longitudinal recesses  25  aligned with the longitudinal recesses  25  of the front face  13  and the back face  15 . The top face  17  further has a transverse recess  27  centrally located on the top face  17  transversely intersecting the pair of longitudinal recesses  25 , creating intersection points  29 . 
     Turning to  FIG. 5 , the recess side face  23  having a transverse recess  27  aligned with the transverse recess  27  of the top face  17 . 
     Turning to  FIG. 6 , the protrusion side face  21  has a transverse protrusion  31  designed to mate with the transverse recess  27  of an other of the building block  11 . 
     Turning to  FIG. 3 , the bottom face has at least one transverse protrusion  31  for mating with a recess  25 ,  27  of a top face  17  of an other of the building block  11 . The transverse protrusion  31  is aligned with the transverse recess  27  of the recess side face  23  and aligned with the transverse protrusion  31  of the protrusion side face  21 . 
     The mortar-less building block  11  has a pair of bores  33 , each bore  33  longitudinally disposed to extend from the intersection points  29  of the top face  17  to the bottom face  19  intersection points  29 , thereby allowing a user to place a rod or pin within the bore  33  of a first building block  11  and within the bore of a second building block  11  when said first and second building blocks  11  are placed on top of each other. 
     In a preferred embodiment, the building block  11  is dimensioned to be a 16″ by 8″ block, a structural block, similar to the traditional masonry block which is standard in the trade. In an alternate embodiment, the block is half scale 8″ by 4″ for use as exterior facing and interior walls. Alternate scales may be employed within the spirit of the invention. 
     Referring to  FIGS. 9-12 , there is shown a joist hanger  35  for supporting a joist (not shown). The joist hanger  35  has an upper anchoring member  37  attached to an upper u-shaped channel  39 , a lower anchoring member  41  attached to a lower u-shaped channel  43 , and one or more connective members  45  connecting the upper u-shaped channel  39  to the lower u-shaped channel  43 , so to receive a joist (not shown) within said upper and lower u-shaped channels  39 ,  43 . The upper anchoring member  37  and lower anchoring member  41  have mounts  47  for alignment with a bore  33  of the block  11  for receiving an anchor such as a rod or a bolt. 
     Referring to  FIGS. 13-14  there is shown a truss bracket  49  for anchoring a portion of a truss to the block  11 . Each truss bracket  49  has a pair of arms  51  connected to a recess channel  53 . The recess channel  53  is adapted to cooperatively fit within the longitudinal recesses  25 ,  125  and/or the transverse recesses  27 ,  127  of the building block  11 . The recess channel  53  further has a bore mount  57  for fixing the truss bracket  49  to a bore  33  of the block  11  with an anchor such as a rod or a bolt. Alternately, holes are drilled into the building block  11 , and bolts and molly-type anchoring systems, or the like are used to fix the truss bracket  49  to the block using the bore mount  57 . The pair of arms  51  further include a plurality of mounts  55  for receiving a fastener such a screw or a nail for fixing the portion of the truss to the truss bracket when the portion of the truss is disposed within the pair of arms  51 . 
     Referring to  FIGS. 4-8 , the present invention further includes a half-block  111  for cooperating with the inventive building block  11  to construct openings such as doorways and windows into a wall. The half block  111  having a front face  113  and a back face  115 , a top face  117  and a bottom face  119 , and a protrusion side face  121  and a recess side face  123  all connected to form the half block  111 . The front face  113  and the back face  115  each having a longitudinal recess  125 . The top face  113  having a longitudinal recess  125  aligned with the longitudinal recess  125  of the front face  113  and the back face  115 , and the top face  117  further having a transverse recess  127  centrally located on the top face  117  transversely intersecting the longitudinal recess  125 , creating an intersection point  129 . 
     Referring to  FIGS. 5-8 , the recess side face  123  has a transverse recess  127  aligned with the transverse recess  127  of the top face  117 . The protrusion side face  121  has a transverse protrusion  131  designed to mate with the recess  25 ,  125 ,  27 ,  127  of an other of the building block  11 , 111 . 
     Turning to  FIG. 8 , the bottom face  119  has at least one transverse protrusion  131  for mating with the top face  17 ,  117  of an other of the building block  11 , 111 . The transverse protrusion  131  is aligned with the transverse recess  27 ,  127  of the recess side face  23 , 123 , and aligned with the transverse protrusion  131  of the protrusion side face  121 . The half block  111 , further has a bore  133  extending through the half block  11  in a direction normal to the top face  117  to enable a rod to be placed through the bore  133  of the half block  111  and into the bore  33 ,  133  of another block  11 ,  111 . 
     The present invention may be embodied as a mortar-less building block system for building a structure. The system comprising the mortar-less building block  11 ,  111  as described herein, a plurality of alignment rods (not shown) a plurality of foist hangers  35 , and a plurality of truss brackets  49 . Preferably, an insulating member (not shown) is disposed exterior to the morterless building block  11 ,  111 . The insulating member preferably is a spray on foam, insulation board, or any other suitable insulating member. 
     The present invention may be embodied as a thermal reservoir structural wall comprising one or more of the components of the system described herein and further comprising an insulating member (not shown) applied to the exterior facing of the block(s)  11 ,  111 . 
     The present invention includes a method of constructing a block wall comprising placing a first block  11 , in a first location; forming a course by mating one side face  21 ,  23  of the first block  11  with a cooperating side face  21 ,  23 ,  121 ,  123  of an additional block  11 ,  111 . One or more additional blocks  111  are laterally interlocked by mating one side face  21 ,  23 ,  121 ,  123  of the one or more additional blocks  11 ,  111  with a cooperating side face  21 ,  23 ,  121 ,  123  of an other of the one or more additional blocks  11 , 111 . 
     A transverse course (that is a course running perpendicular to the course) is formed by mating one recess  25 ,  125  of the front face  13 ,  113  or back face  15 ,  115  of the first block  11  with a protrusion side face  21 ,  121  of an additional block  11 ,  111 . Additional transverse courses may be formed by mating one recess  25 ,  125  of the front face  13 ,  113  or back face  15 ,  115  of another block  11  with a protrusion side face  21 ,  121  of an additional block  11 ,  111 . 
     One or more additional blocks  11 ,  111  are laterally interlocked by mating one side face  21 ,  23 ,  121 ,  123  of the one or more additional blocks  11 ,  111  with a cooperating side face  21 ,  23 ,  121 ,  123 , of the one or more additional blocks  11 , 111 . 
     A second transverse course is set by mating the transverse protrusion  31 , 131  of the bottom face  19 ,  119  of an additional block  11 ,  111  with a longitudinal recess  25 ,  125  of the top face of the first block; 
     A second course is set by mating the transverse protrusion  31 , 131  of the bottom face  19 ,  119  of an additional block  11 ,  111  with a transverse recess of the top face of the first block; 
     Additional courses are set by mating the transverse protrusion  31 , 131  of the bottom face  19 ,  119  of an additional block  11 ,  111  with either a transverse recess  27 ,  127  or a longitudinal recess  25 ,  125  of the additional blocks  11 ,  111  disposed on the lower courses 
     The bore  33 ,  133  of the additional block  11 ,  111  is aligned with the bore  33 ,  133  one or more additional blocks  11 , 111 , and a rod or pin is inserted into a bore of one block  11 ,  111  and extending the rod or alignment pin into a bore  33  of one or more additional blocks  11 ,  111 . 
     A joist hanger  35  is set by aligning the mount  47  of the upper anchor member  37  with a bore  33  on the top face  17 ,  117  of a block  11 ,  111 . The mount  47  of the lower anchor member  41  is also aligned with a bore on the bottom face  19 ,  119  of the block  11 ,  111 . A pin or a rod is passed through the mount  47  of the upper anchor member  37 , though the bore  33  of the block  11 ,  111 , through the lower anchor member  41  of the joist hanger  35 , and preferably through a bore  33  of another block  11 ,  111  situated above or below the joist hanger  35 . 
     A truss bracket  49  is provided to mount a truss member (not shown) to a wall constructed of block  11 ,  111 . The truss bracket  49  is fixed to a block  11 ,  111  by aligning the bore mount  57  with a bore  33  of the block  11 ,  111  and inserting a bolt, rod, or pin to fix the truss bracket  49  to the block  11 ,  111 . Alternately, other anchoring systems (such as drilling holes and/or inserting molly anchors and bolts) can be used to fix the truss bracket  49  to the wall. 
     For interior finishing, a flush support bracket may be utilized, which comprises a recess fitting member connected to or integral with a recess extending member. The recess fitting member is adapted to fit within a recess  25 ,  125 ,  27 ,  127  of a block  11 ,  111  and extend beyond the face of the block  11 ,  111  to allow attachment of junction boxes and the like. 
     Although particular embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those particular embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.