US20080060313A1

US20080060313A1 - Split-Face Block Mold

Info

Publication number: US20080060313A1
Application number: US11/677,787
Authority: US
Inventors: Douglas Eugene Edwards
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-08-22
Filing date: 2007-04-11
Publication date: 2008-03-13

Abstract

The invention is to make a mold that will make a square 12×8×12 block that when split makes a full 6×8×12 and a half block that will be used in a construction system based on the combined use of split-face mortar less blocks designed to lock together. There are two basic blocks, the full, and half block, with which any desirable structure can be built. The full block has protruding ears and grooves. The half block also has protruding ears and grooves. There are standard measurements between groove face in all blocks and standard measurements between ears in the full block which correspond to the measurement of the groove faces. This provides for a wide array of interlocking positions.

Description

Mold for making mortar-less interlocking, split-face blocks, made by changing and deleting some parts of the mold described in U.S. Pat. No. 4,896,472, which makes the regular interlocking block, so that the resulting mold will produce a 12″×8″×12″ block that can be split into 6″×8″×12″ split-face block and/or produce a 16″×8″×16″ block that can be split into two 8″×8″×16″ split-face blocks.

OBJECTIVE OF THE INVENTION

The objective of the invention is to build mortar-less, interlocking, split-face blocks for construction of residential dwellings and commercial buildings that require no skilled labor.

BACKGROUND OF THE INVENTION

The invention relates to a building block and a system to facilitate the construction of buildings, walls, cross walls and the like without the need of special equipment or techniques. The essential idea is to provide a full block and a system using the full and two other types of interlocking blocks, the basic system being three blocks. The blocks are designed to firmly lock together and thus the construction does not require the traditional mortar or cement to bond it together. This is due to the selection and position ears protruding from at least the full block and grooves in all the blocks that fit on said protruding ears. As a result, it is possible to interlock said blocks in parallel, longitudinally or transversely. Thus, with this system any simple or complex structure may be built.
This application claims a benefit of an earlier provisional application 360/839,200 filed Aug. 22, 2006. Also applicants are elderly, one is 78 and the other is 80 so we wish to ask for and expedited application process.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The system comprises the combination of two basic building blocks: a full block; and a half block.
These blocks should be manufactured with precision for interlocking without the use of mortar. Load-bearing structures can be built therewith.

The Full Block

As shown in FIG. 1, the full block is a rectangular configuration of two spaced, parallel end walls and two spaced, parallel side walls extending longitudinally of the block between the therefore transverse end walls. The side and end walls have respective external faces 101, 102 and define an open-ended internal cavity extending between top and bottom faces 108,109, respectively, of the walls and, therefore, of the open-ended internal cavity.
The middle web 103 extend transversely of said block and, therefore, parallel to it end walls between internal faces of the side walls for separating the open-ended internal cavity into two end cavities of substantially equal size of one end wall, one internal face of one end wall, one internal face of one middle web, and the intervening internal faces of side walls.
An ear 107 on a central web protrudes from the top face 108, each ear being of substantially the same dimensions. Each ear has a transversely extending surface 104 delimiting the extent of said ear toward said central web and oppositely disposed, longitudinally extending surface 114, each delimiting the extent of said ear toward the proximal wall.
A groove is in the internal face of the end and side walls of each end cavity. Each said groove extends from the bottom face 109 toward the top face 108 at least as far as the ears 107 project from the top face 108. Each groove is defined by a groove face 100 and adjacent opposite edges 106.
The side edges 106 of the groove in each end wall are each spaced from the external face 101 of the proximal side wall a distance x substantially the same as the distance from the longitudinally-extending surfaces 114 of the ears 107 respectively to the same, proximal side wall faces. Each transversely-extending surface 104 of each ear is spaced from the external face 102 of the proximal end wall a distance Y substantially one half the external length of a side wall minus the distance Z of the face of the groove 100 Z in the proximal end wall to said external face 102 Z of said end wall. The side edge 106 Z proximal the end wall of the groove in each said side wall is substantially the same distance ZX from the external face 102 Z of said proximal end wall as the distance X of each longitudinally-extending surface 114 of each ear to the external face 101 of the proximal side wall.
As a result, as shown in FIG. 1, an ear and groove of three adjacent blocks A, B and D or B, C and E can be male-female interlocked with external side and end faces of one bloc flush in a longitudinal orientation, like block A, B and D, or transverse orientation, like blocks B, C and E. The full block is such, therefore, that three such blocks in sequence are adapted to form a running bond of longitudinal or transverse orientation of the sequential full blocks. In the longitudinal orientation, each groove 100AD, 100BC in each end wall of one full block D respectively male-female interlocks with one ear 107AD, 107BD of each of the other two full blocks a, B the external faces 102 of the end walls of the other full blocks A, B being in mating relationship at 102 and the external faces 101 of the side walls of each full block being parallel and respectively flush with the external faces of the side walls and one groove 100 CE in one side wall of one full block E respectively male-female interlocks with one said ear 107BE, 107CE of each of said other two full blocks B, C, the external faces of side walls 101 of full E block being transverse to the external faces of the side walls 101 of at least one of said other two full blocks B, C.
In other words each groove extending from the bottom toward the top face at least as far as the ears project from the top face is positioned, shaped and dimensioned so that an ear and groove of adjacent block can be male-female interlocked with one external face of one block flush with an external face of another block foe either longitudinally or transverse orientations of the blocks.

Mold Design

In the manufacture of conventional blocks only one bar 400B is used for the cores. The bar 400B is located along the top face of a mold for concrete blocks to support steel cores 401B to form a cavity or hollow in a concrete block. The mold method herein described uses twin, i.e. two parallel-spaced core bars 400A for supporting steel cavity-forming 401A in a block forming press mold. The positions of the twin bars 400A can be approximately 6 mm from opposite longitudinal edges (114 in FIG. 3) of the protruding ear 107 to a position of approximately 3 mm with relation to the external edge of the steel core.
Molding guides 407 in FIG. 4 on sections of the twin bars at the area of the top face 403A and extend downward between the steel cores 401A to the frits levels defined by top face 404A (108 in FIG. 4) of said block aside from the ear projections. These are in the 6 mm space between the twin bars 400A and the longitudinal sides face 408A of the projections at 403A as delimited by the steel cores 401A. The molding guides 407 are removable.
The contours are such that each external face has at least one protruding portion 150 and at least one receding portion 152, the side external faces each having two of each such potions. The depth from and into the block of the protruding and receding portion of the contours together define an average face (only one shown) at 154 of each wall which is shown in phantom because not real. The average face at 154 corresponds to the face from which various distance have heretofore been described as being measured.
In the embodiment of FIG. 2, the average face of the walls corresponds with the non contoured portion of the side and end external faces 101′, 102′ at the ends of each wall and also at the middle of the side walls. A marker groove 156 extends parallel to the contours at the middle of the side faces to mark this location for alignment with an edge of an end or side face of another full block in a construction of such blocks. This helps get the external faces of the block flush in transverse orientation of the blocks and helps position the blocks in a construction for the grooves and ears to interlock.
The protruding and receding portion of the contours on opposite end and side faces of the block are complimentarily positioned for nesting with those of another full block similarly oriented relative to the top and bottom faces when complementary end or side faces of the blocks mate. This prevents relative movement of the blocks transverse of the contours and, when there are two such blocks with the ears and grooves thereof interlocked, too, adapts the block for forming rigid structure.
It will be understood that various other characteristics and features of the invention are apparent from the drawings that such variations of any characteristics or features of the invention as may occur to one of ordinary skill in the art are contemplated by the following claims to the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Merely-preferred embodiments, which do not limit the invention, are shown in drawings, wherein:
FIG. 1 is a prospective top and bottom view of a group of full blocks.
FIG. 2 is a bottom view of a block before it is split to make a 6×8×12 split-face block.
FIG. 3 is a top plain view of a shoe assembly of the block molding. It is also a top view of a block before it is split to make a 6×8×12 split-face block.
FIG. 4 is a cross sectional view of the end of the mold design.
FIG. 5 is a longitudinal, side cross-sectional view
FIG. 6 is a transverse end cross-sectional view.
FIG. 7 Bottom View (female) side A and Side B are identical and is a unit when molded. Once Side A and Side B are split apart forming two whole split-face blocks, Side A and/or Side B may be split again to form half split-face blocks. XX shows the splits.
FIG. 8 is a view showing the full block except the slots 100-106 is not shown. Under the ears, the twin bars for making the ears are in the drawing also.
FIG. 9 is a cut-away view of an exploding full block.

Claims

1. A building system comprising of two types of split face interlocking blocks, whereby construction of structures therewith does require mortar to lay the first course for the Initial leveling of the wall; also grouting the cells with rebar, and the ring beam, the two types of blocks comprising:

a. A split face full block of rectangular configuration: two spaces, parallel end walls and parallel side walls extending longitudinally of the block between the end walls, the end and side wall faces middle web extending transversely of the block and parallel to the end walls between internal faces of side walls for separating two end cavities of equal size, each end cavity being defined by an internal faces of one end wall, one internal face of the middle web, and the intervening internal faces of the side walls; and ears on middle web, the ears being confined to and protruding from middle web and being the only protrusion from the top face, each ear being the same dimensions; and a groove in the internal face of each of the end and sidewalls of each cavity being non-contiguous, each groove extending from the bottom face toward the top face at least as far as the ears projecting from the top face and being positioned, shaped and dimensioned so that an ear and groove of adjacent blocks can be male-female interlocked with one external face of one block flush with an external face of another block for either longitudinally parallel or transverse orientation of the respective blocks.

b. The full split face block wherein one external side face has a split face and one external side face has the same configuration as the external end faces of the full block are contoured along axes perpendicular to the top and bottom faces of the full block so that each face has at one protruding and one receding portion, the respective protruding and receding portions mating with each other so that when an external end or side face of one full block is in mating relationship with an external face of another full block, relative movement of the blocks transversely of the axes is prevented.

c. The split face full block wherein the one external face and external end faces of the full block are contoured along axes perpendicular to the top and bottom faces of the block so that each face has at least one protruding and at least one receding portion, the respective protruding and receding portion mating with each other so that the split face block is adapted to form a rigid structure. This is achieved when at least two other full blocks are interlocked between respective ears and grooves respectfully.

2. A split face half block of square configuration comprising four walls, each having an external face and internal face, the internal face defining one internal cavity, two of the external faces of the half block each having the same configuration as the external faces of the end walls of the full block, and at least one groove in the internal face of the half block extruding from one end of the cavity for male-female fitting with one ear of the full block in the construction of a structure.

3. Wherein the split face half block further comprise a groove on three internal faces thereof, the grooves being non-contiguous.

4. Wherein the split face half block does have protruding ears.

5. And further comprising a plurality of the split face block piled upon another to define a cavity for reinforcing with rebar to form a column and pillar.

6. The building system according to claim 2, wherein the two external faces of the split face half block each have the same dimensions and each groove is located in the same position with respect thereto.