Static structures (e.g. – buildings) – Processes – Barrier construction
Reexamination Certificate
1998-02-09
2001-10-09
Silbaugh, Jan H. (Department: 1732)
Static structures (e.g., buildings)
Processes
Barrier construction
C052S747100, C264S259000, C264S275000, C264S278000, C264S279000, C264S271100, C264S297900, C264S333000, C156S304100, C156S304500, C425S117000
Reexamination Certificate
active
06298632
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to masonry construction. More specifically, the present invention pertains to building block units, installation of building block units and methods of manufacturing and utilizing such. In particular, the present invention pertains to a unique building block unit or modular building unit in which a standard brick or other type of building block is placed in a mold and a mounting strip applied to faces of the brick or other type building block and allowed to set as an additional manufacturing step to form the building block unit.
2. Description of the Prior Art
Masonry construction, one of the traditional methods of building, has been utilized for many centuries. Masonry, simply stated, is the assembly of building block units, such as bricks, stone, concrete, etc., by laying such units adjacent to each other in a composite wall, column or other structure. These units are typically joined by some type of mortar which is wet and mixed and applied to the surface of one building unit or block adjacent thereto. The mortar sets up, cementing the building units together as it hardens. Such masonry construction has distinctive architectural characteristics which have been desired throughout the ages, still being the type of construction preferred by many.
Because of its strength, relative uniformity, appearance and other characteristics, the brick, and especially the fired clay brick, has been one of the most used and desired building units for masonry construction. The typical brick is in the shape of a rectangular box and in building a wall with bricks, layers of bricks are laid in stepped or staggered relationships so that an overlying brick straddles the joint of a pair of underlying bricks. While the typical rectangular box-like brick is most common, a number of brick and other building block shapes have been developed over the years to obtain enhanced appearances, more uniform construction, or other characteristics sought for masonry construction. Examples of such specially designed bricks or building blocks may be seen in U.S. Pat. Nos. 3,299,599; 3,479,782; 3,936,987; 4,091,587; and 4,124,961. In fact, there are countless shapes and designs in bricks and other building blocks.
The typical kiln fired bricks utilized in masonry construction are made of clay or shale. The bricks are typically molded, dried and burned in kilns. There are several methods of molding bricks and other building blocks. There are several qualities of bricks and other building blocks, quality being determined by strength, durability, etc. One of the major problems associated with masonry construction is the nonuniformity of building block dimensions due to shrinkage, warping, twisting, etc. Because of these characteristics, mortar is necessary not only to bond the bricks or other building blocks together, but to smooth out the irregularities thereof.
Another major problem associated with masonry construction is the mortar materials utilized to bond the bricks or other building blocks together. In many respects, mortar is the weak link in masonry construction. It normally has less compressive and tensile strength than the building blocks it joins. The shear strength of masonry is a function of the bond strength of mortar to the associated brick or other building block and frictional resistance at the building block-mortar interface. The water tightness of masonry construction is primarily dictated by the characteristics of the mortar which is more water permeable than brick and most other building block materials. While so much depends on the quality of mortar used, mortars are typically mixed at the job site and can easily be incorrectly mixed or used beyond its useful mix life. Thus, even though masonry construction has been utilized for centuries, there are still some inherent problems pertaining to the lack of uniformity of quality and dimensions in the brick or other building blocks and to the weaknesses associated with the mortars used therewith. Accordingly, the search continues for improved masonry construction.
The prior art is generally directed to building units which have blocks in a flush relation to each other and do not include a separate mounting strip extending about the entire periphery of a block for separating adjacent blocks from each other. U.S. Pat. No. 2,077,750 dated Apr. 20, 1937 shows a mounting border along opposed sides of a building block but not about the entire periphery of the building block. U.S. Pat. No. 4,426,815 dated Jan. 24, 1984 likewise does not show a separate mounting strip secured about the periphery of a block and adjacent blocks are in flush relation to each other, not separated by a mounting strip or the like.
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a unique dimensionally accurate building block unit and method of manufacturing such. The term “building block unit” or “modular building unit” as used herein refers to a brick or other building block in combination with a separate mounting strip preferably formed of mortar which together form a manufactured masonry building block unit for delivery to a building site. While the building block unit of the present invention may utilize brick or other building blocks, the goal is not to redesign the building block per se but to combine the building block with new materials and technology to produce a unique combination. The result of the design and control of building block unit is to make it modular, self-aligning, self-leveling and self-plumbing. The dimensional control of the building block unit is essential for its use in modular construction including a plurality of interfitting building block units. The product is to be a dimensionally accurate building block unit with a separate mounting strip secured to the block in an additional manufacturing step.
The building block unit of the present invention may include a brick or other building block defining a rectangular parallelepiped having parallel rectangular upper and lower faces, parallel rectangular side faces, and parallel rectangular end faces. The upper and lower faces and sometimes one or more of the end faces or a portion of one of the side faces is provided with a mounting strip such as a layer of preapplied and preset mortar. Throughout this description, the terms “preapplied” and “preset” may be used. As used herein, the term “preapplied” simply means the mounting strip or mortar is applied as a manufacturing step. The term “preset” means that the mounting strip is applied and allowed to set prior to use in the field. The preset mounting strip of the building block unit interfits with all mounting strips of mating building block units to connect the building block units together in a predetermined dimensionally accurate relationship. Mounting strips on adjacent mating building block units are secured to each other by a suitable adhesive.
As indicated, the mortar forming the mounting strips of the building block unit of the present invention is preapplied to the building block by a molding process and preset prior to shipment to the field or place of installation. The mounting strip of one building block unit interfits with the mounting strip of an adjacent building block unit. Recessed slots and protruding keys or projections may be provided on adjacent layers of the present building strips for interfitting with corresponding correlative keys and slots, respectively, of adjacent building block units to assure proper orientation thereof. Methods of manufacturing the building block units will be more fully described hereafter.
The preapplication and presetting of mortar on each building block (prior to installation) assures a dimensionally accurate composite building block and when interfitted to adjacent building block units results in a predetermined dimensionally accurate construction. Not only is the final construction dimensionally accurate, it is much stronger and has characteristics which are improved over the prior art,
Poe Michael I.
Silbaugh Jan H.
LandOfFree
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