US20040237444A1

US20040237444A1 - Grout block

Info

Publication number: US20040237444A1
Application number: US10/448,619
Authority: US
Inventors: Samuel Dunavant
Original assignee: Individual
Current assignee: Individual
Priority date: 2003-06-02
Filing date: 2003-06-02
Publication date: 2004-12-02

Abstract

A building block is described, which has a recessed grout trough at its mid-perimeter, top, bottom and ends. It has a hollow core and beveled edges. After each row of block has been positioned, a liquid grout is poured into the grout trough at the end of each block and flows downwardly and into the bottom trough, before setting up.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

NOT APPLICABLE

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

NOT APPLICABLE

INCORPORATED-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

NOT APPLICABLE

BACKGROUND OF THE INVENTION

(1) Field of the Invention

This invention is directed to a masonry building block having recessed troughs to contain liquid grout.

Beginning with the earliest civilizations, men have been constructing walls and other structures of masonry blocks. And through the centuries the technology and techniques have little changed. Initially, large blocks were shaped out of stone and stacked on one another. Their size and weight were sufficient to maintain them in their stacked assembly. Later, bricks were formed of sun-dried clay. Being smaller and lighter than stone blocks, bricks could not be simply stacked. So a cementitious mortar was used between the bricks to maintain them in their stacked assembly. In more recent years, cinder block has been widely used. Like brick, cinder block requires mortar. The technique is the same. An initial row of brick or block is laid on a stable surface with mortar applied by trowel between adjacent ends and a layer of mortar is applied by trowel to the top surface of that row; then the next row is laid in a similar manner on top the initial row. Each individual brick is positioned so that the vertical mortar joint extends directly above the middle of the brick in the row beneath. Subsequent rows are laid in a similar manner as the wall ascends.

One advantage of brick and cinder block over larger stone block is that being smaller and lighter, they can be more easily lifted and positioned by the masons building the wall. One disadvantage is the mortar joint. It breaks up the monolithic appearance of the wall and is unaesthetic. Another disadvantage is that a high degree of skill is required in laying the brick or block and applying the mortar. It must be applied evenly and consistently. For reasons of economy, it must also be applied as quickly as possible. Needing skilled masons to lay walls or other such structures of brick and block, adds greatly to the cost of such construction. Furthermore, the possibility of mortar which is improperly mixed or applied, creates the risk of a structure that is not safe and stable.

It is accordingly, an object of the present invention to provide a masonry building block which does not require mortar and can be assembled to form a stable wall or other such structure having a monolithic appearance.

(2) Description of Related Art

Applicant is aware of no prior art directly relevant to the present invention. In the Office Action of Mar. 24, 2004, four prior U.S. patents were cited: U.S. Pat. No. 5,881,524, No. 4,794,749, No. 5,379,562 and No. 6,204,0688.

BRIEF SUMMARY OF THE INVENTION

In accordance with the present invention, a building block has a recessed grout trough at its mid-perimeter, top, bottom and ends. It also has a horizontal hollow core and beveled edges. The block can be laid dry without mortar. After each row of block has been positioned a liquid grout is poured into the grout trough at the end of each block.

It flows down the end trough into the bottom trough. The grout sets up quickly and firmly adheres each block to the adjacent block. The assembled block present a monolithic surface with no mortar joints.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an elevation view of the top of a standard in-line block [0013]
FIG. 2 is an elevation view of the left side of the block shown in FIG. 1 [0014]
FIG. 3 is an elevation view of the right side of the block shown in FIG. 1 [0015]
FIG. 4 is an elevation view of the front of a standard in-line block [0016]
FIG. 5 is an elevation view of the left side of the block shown in FIG. 4 [0017]
FIG. 6 is an elevation view of the right side of the block shown in FIG. 4 [0018]
FIG. 7 is an elevation view of the top of a corner block [0019]
FIG. 8 is an elevation view of the left side of the block shown in FIG. 7 [0020]
FIG. 9 is an elevation view of the right side of the block shown in FIG. 7 [0021]
FIG. 10 is an elevation view of the front of a corner block [0022]
FIG. 11 is an elevation view of the left side of the block shown in FIG. 10 [0023]
FIG. 12 is an elevation view of the right side of the block shown in FIG. 10 [0024]
FIG. 13 is an elevation view of the top of a foundation wall laid with the grout block [0025]
FIG. 14 is an elevation view of the front of a foundation wall in FIG. 13[0026]

DETAILED DESCRIPTION OF THE DRAWINGS

Reference will now be made to the preferred embodiment of the invention as illustrated in the accompanying drawings. [0027]
The standard in-[0028] line block 1, is illustrated in FIG. 1 through 6. It has an inner revetment 2, which extends around its inner periphery. It has an outer revetment 3, which extends around its outer periphery. The “outer periphery” refers to that side of the block which forms the outer surface of a wall, the surface which is generally visible.
A [0029] top trough 4 is formed between top revetments 2 and 3. Side trough 5 is similarly formed between side revetments 2 and 3. A bottom trough 6 is formed between bottom revetments 2 and 3. The block 1 has an outer face surface 8. There is a beveled edge 7 on the outer revetment 3, which frames the face surface 8.
The [0030] corner block 10 is illustrated in FIG. 7 through FIG. 12. It has an inner revetment 12, which extends around its inner periphery. It has an outer revetment 13, which extends around its outer periphery.
A [0031] top trough 14 is formed between top revetments 12 and 13. Side trough 15 is similarly formed between side revetments 12 and 13. A bottom trough 16 is formed between bottom revetments 12 and 13. The block 1 has outer face surfaces 18 and 19. There is a beveled edge 17 on the outer revetment 13, which frames the faces surfaces 18 and 19.
The [0032] inner revetment 12 has a gap 11, which is the same width as trough 14 (i.e., eight inches). Gap 11, functions as an opening to trough 14. When the corner block 10 is laid in a course of blocks, it has a standard block 1, next to it and in line with it on one end.
The [0033] inner revetment 12 has a gap 11, which is the same width as trough 14 (i.e. eight inches). Gap 11 functions as an opening to trough 14. When the corner block 10 is laid in a course of blocks, it has a standard block 1, next to it and in line with it on one end. It has another standard block 1, perpendicular to its other end. The top trough 4 of the standard block 1 in line with the corner block 10, is contiguous with the top trough 14 of corner block 10. The top trough 4 of the standard block 1, perpendicular to corner block 10, is contiguous with gap 11.
Although not specifically illustrated in the drawings, it should be understood that the bottom side of [0034] corner block 10 is the same as the top side, in that it has a gap in the inner revetment making bottom trough 6, contiguous with bottom trough 16. Therefore, the same corner block used in a left-hand corner is simply inverted to use in a right-hand corner.
It will be appreciated from the structure as described above, that (as illustrated in FIG. 13) the contiguity of the [0035] top trough 4, and top trough 14 (with gap 11) provides an unimpeded trough around the entire perimeter of the wall. It should also be understood that the bottom surface of each block 1 and block 10, is identical to its top surface. So each is invertible. As illustrated in FIG. 14 when a course of block 21 is placed over the course 22 immediately beneath it, the top troughs 4 and 14 of the course 22 align with the bottom troughs 6 and 16 of course 21. So the troughs 4 and 14, covered with troughs 6 and 16, form an unimpeded channel which extends around the entire perimeter of the wall.
The standard block has a cavity [0036] 9 formed through its middle. The corner block 10, has a similar cavity 20 formed through most of its middle but terminating short of the end face surface 19. The purpose of cavities 9 and 20 is to make the blocks lighter in weight and better insulating. The cavities 9 and 20 are filled with light weight insulating material such as plastic foam.
One development, which makes the present invention possible and practical, is recently available non-shrink grouts, which are of low viscosity and readily pourable. [0037]
After the [0038] course 21 of blocks 1 and 10 has been laid, low viscosity grout is poured into side troughs 5 and 15 up to and even with the top troughs 4 and 14. The grout being only slightly thicker than water, quickly flows down the side troughs 5 and 15, and then into the unimpeded channel formed by the confluence of troughs 4 and 14 with troughs 6 and 16 which extends around the perimeter of the wall. The grout does not flow into cavities 9 and 20 because they are filled with plastic foam or other insulation material. In an alternative form of the invention, where cavities 9 and 20 are not filled with insulation, the opening ends of cavities 9 and 30 are covered with caps of light weight inexpensive material like cardboard or plastic sheet, so that the grout does not flow into cavities 9 and 20. The grout will flow into the tiniest crevices and when hardened will completely seal and bond the blocks together. The next course of blocks is then laid with vertical joints falling at mid-block of the course below and the process is repeated up to the top of the wall in a pattern similar to conventional block laying. Reinforcement bars of metal may be placed in the troughs before grout is poured to further strengthen the wall.

Claims

What is claimed is:

1. (Original-cancelled) The recessed grout trough around the mid perimeter of the grout block.

2. (Original-cancelled) The hollow horizontal cavity through the center of grout block.

3. (Original-cancelled) The beveled edges on the front and back faces of grout block (see drawings).

4. A block wall construction comprising:

a plurality of in-line blocks, each of said blocks having an inner face surface, an outer face surface and an exterior perimeter surface extending between said face surfaces.

revetments formed on the inner and outer edges of said exterior perimeter

recessed grout troughs formed between said revetments

said in-line blocks laid in courses between corner blocks

said corner blocks have an inner face surface, an outer face surface, and an end face surface extending perpendicularly between one end of said inner face surface and the corresponding end of said outer face surface

each of said corner blocks having an exterior perimeter surface extending between said face surfaces

revetments formed on the inner and outer edges of said exterior perimeter

a recessed grout trough formed between said revetments

a gap formed in the revetment on the inner edge of the exterior perimeter

said gap being contiguous with the grout trough of the in-line block adjacent thereto

5. An in-line building block comprising:

an inner surface, an outer face surface, and an exterior perimeter surface extending between said face surfaces

revetments formed on the inner and outer edges of said exterior perimeter

recessed grout troughs formed between said revetments and not visible on said surfaces

6. A corner building block comprising:

an inner face surface, an outer face surface, and an end face surface extending perpendicularly between one end of said inner face surface and the corresponding end of said outer face surface

said corner block having an exterior perimeter surface extending between said face surfaces

revetments formed on the inner and outer edges of said exterior perimeter

accessed grout trough formed between said revetments

a gap formed in the revetment on the inner edge of the exterior perimeter

7. The block of claim 5, having a hollow core

8. The block of claim 7, wherein said hollow core is filled with light weight insulation material

9. The block of claim 8, wherein said insulation material is plastic foam

10. The block of claim 7, wherein each end if the hollow core is covered with a cap to prevent poured grout from entering said hollow core.

11. The block of claim 5, wherein the outer face surface has a beveled edge around its periphery

12. The corner block of claim 6, wherein the outer face surface and the end face surface have beveled edges around their periphery

13. The corner block of claim 6, having a partial hollow core, open on one side but closed from the end face surface side

14. The corner block of claim 13, wherein said hollow core is filled with light weight insulation

15. The block of claim 14, wherein said insulation material is plastic foam

16. Currently amended) The block of claim 7, wherein the open end of the hollow core is covered with a cap to prevent poured grout from entering said hollow core