Static structures (e.g. – buildings) – Module or panel having discrete edgewise or face-to-face... – With joining means of dissimilar material and separate from...
Reexamination Certificate
1999-01-08
2001-02-20
Stephan, Beth A. (Department: 3635)
Static structures (e.g., buildings)
Module or panel having discrete edgewise or face-to-face...
With joining means of dissimilar material and separate from...
C052S605000, C052S586100, C052S585100, C052S586200
Reexamination Certificate
active
06189282
ABSTRACT:
BACKGROUND
Conventional concrete blocks have the advantages in construction of low material cost, durability, strength and simplicity. However, assembly into a useful wall requires considerable time, skill and almost continuous use of mortar. Workers must set each block on top of a bed of mortar, and then tap the block until the block is plumb, flush with the wall and at the correct height. Thus, block stacking is time-consuming and requires considerable training. Moreover, rain or subfreezing weather conditions can prevent proper curing of the mortar. Measures can be taken to allow construction in such weather conditions but can be economically unfeasible. As a result, work is usually suspended during adverse weather conditions.
Various attempts have been made to produce mortarless or dry-stack blocks where blocks are stacked to form walls with no intervening mortar in order to avoid the problems associated with the use of mortar. A problem with mortarless blocks is that conventional block making equipment cannot consistently manufacture blocks with height tolerances of less than {fraction (1/16)} inch. In a block wall having a running bond pattern (each block resting on two blocks below), such height variations are too large for building stable mortarless walls. Typically, in conventional block walls, the mortar compensates for the height variations in the blocks. Most current mortarless blocks have designs which compensate for height variations but are either uneconomical to manufacture or require too much skill and time to assemble, thereby defeating the advantages of mortarless blocks.
SUMMARY OF THE INVENTION
The present invention is directed to a block system that does not require mortar and is economical to manufacture and assemble. The block system includes first and second blocks each having an outer surface with a first pair of locking channels formed within the outer surface. The locking channels are spaced apart from each other. Each locking channel has a narrower outer slot portion extending through the outer surface and a wider inner slot portion extending from the outer slot portion into its respective block. A first pair of locking members are provided for coupling the blocks together by insertion into the locking channels of the blocks with the locking channels of the first block being positioned to join with the locking channels of the second block. The locking members have a cross-section with wider outer edges dimensioned to fit in the inner slot portions and a narrower mid-section dimensioned to fit in the outer slot portions.
In preferred embodiments, the blocks are made of concrete and are rectangular with corners. Each locking channel is positioned close to a corner. The locking members have a continuous outer surface and are preferably solid with tapered ends. Each block further includes a second pair of locking channels. In one embodiment, the first and second pairs of locking channels are on opposite sides of the blocks. Each pair of locking channels are positioned on a web. The web is adjacent to a cavity extending through the block and is thicker near the locking channels. In another embodiment, the first and second pairs of locking channels are at right angles to each other. In addition, in another embodiment, a pair of locking passages extend through each block and are capable of engaging the locking members, thereby enabling the first and second blocks to be stacked in an offset manner.
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Building Works, Inc.
Dorsey Dennis L.
Hamilton Brook Smith & Reynolds PC
Stephan Beth A.
LandOfFree
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