US2157992A - Building block and assembly thereof - Google Patents

Description

May 9, 1939. L c M H 2,157,992

. BUILDING BLOCK AND ASSEMBLY THEREOF Filed Dec. 16, 1936 I 2 Sheets-Sheet l tazzzm afzzf/ May 9, 1939. I c sMlTH 2,157,992

BUILDING BLOCK AND ASSEMBLY THEREOF Filed Dec. 16, 1936 2 Sheets-Sheet 2 I Z Z i7 463 q Aw /o 47 V0 5 Zfl 2/ 02%fi %%Wjfl Patented May 9, 1939 UNITED QFFICE Leonard C. Smith,

East Chicago, Ind.

Application December 16, 1936, Serial No. 116,047

8 Claims.

My invention relates to building blocks such as are usually made of concrete or similar material and refers more particularly to molded blocks of the type adapted to be used in the construction of walls and partitions having air spaces therein.

In building construction it is important to minimize the conductivity of heat and moisture through the walls, this being preferably accom- 10 plished by providing dead air spaces between inner and outer portions of the wall. It is essential, however, that the inner and outer portions of the wall be united through the intervening air spaces to assure adequate structural strength and without providing avenues for heat or moisture conductivity between the inner and outer wall portions which would appreciably impair the efiectiveness of the insulating air space therebetween, and this has not been accomplished satisfactorily heretofore in walls made up of building blocks as the prevailing practice is to construct such blocks with openings which are cored out between the inner and outer portions of the block, so as to leave connecting webs through which heat and moisture are quite readily communicable from the outer face to the inner face of the block.

The principal objects of my invention are to provide building blocks of an improved form for making hollow walls which are effectively insulated against communication of heat or moisture therethrough; to provide a simple form of block which is easily manufactured and with a minimum of material; to utilize separate blocks for the inner and outer portions of the hollow wall; to interlock the inner and outer blocks and in a manner to eliminate any appreciable communication of heat or moisture through the wall; to interlock the blocks at the outer side of the wall, and likewise the blocks at the inner side thereof, by the same means which interlock the blocks of one side with the blocks of the other side; to utilize the interlocking means not only to assure accurate spacing of the blocks at one side of the wall from the blocks at the other side of the wall but also to facilitate and insure accurate alignment of the blocks at each side of the wall; to avoid direct connection between opposed inner and outer blocks by arranging the interlocking between courses in such a manner that the blocks of each course or tier at either side of the air space is interlocked with the courses or tiers of blocks thereabove and therebelow at the opposite side rather than with the course or tier directly opposite; and to provide chases which will accommodate vertical and hori- Zontal pipes in the wall as well as permit utilization of selected portions of the air space for air ducts, or for vertical or horizontal filling, re- 5 inforcing and floor connections; these and other objects being accomplished as pointed out hereinafter and as shown in the accompanying drawings in which:

Fig. l is a perspective view, with portions cut away, of two intersecting walls made up of building blocks constructed in accordance with my invention;

Fig. 2 is a perspective View of my building block showing the inner side thereof; 15

Fig. 3 is a similar view of a modified form of my building block;

Fig. 4 is a perspective view of a special end block;

Fig. 5 is a perspective view of a special filler block;

Fig. 6 is an enlarged vertical section of a portion of the wall structure of Fig. 1 taken on the line 6-5 of Fig. 1, but showing connections for a floor which is omitted in Fig. 1;

Fig. '7 is a vertical transverse section of the wall of Fig. 6 showing a floor connected therewith; and

Fig. 8 is a horizontal section on the line 88 of Fig. '2.

Referring to the drawings, the reference numeral it! indicates as a whole the standard form in which I prefer to construct my block, as distinguished from special forms which may be required for wall ends, corners and other purposes, said standard block it consisting of a rectangular panel portion l l having a lateral extension 52 at each end, both extensions being preferably notched at their outer ends as indicated at It so that each of said lateral extensions !2 terminates in spaced upper and lower lugs 14. These lateral extensions ii are of the same width as or vertically commensurate with the panel portion l l f the block, and each extension [2 is provided with two semi-circular grooves l5 in the top and bottom edge faces respectively thereof, the grooves 55 at the top being in alignment as are also the grooves 55 at the bottom and all of the grooves l5 being equallydistant from the plane 50 of the outer face of the panel il, all as shown particularly in Fig. 2 which illustrates my preferred standard form of block. Preferably also each notch it is formed with grooves It in the opposite side walls for interlocking engagement 55 with a filler member which may be used with the standard form of block to close off selected areas of the air space within the wall to provide air ducts, pier molds and the like as will be more fully explained hereinafter.

In assembling a wall therefrom these blocks I0 are laid up in successive superposed courses with cement or mortar between the ends of adjoining blocks and between the superposed courses thereof, each course consisting of two opposed rows of blocks IB which are arranged end toend in staggered relation with the lateral extensions I2 of the adjoining blocks of each row in side by side relation and projecting inwardly toward the center of a block it at the opposite sideof the .wall, but terminating at a distance therefrom, the rela- 'tive location of the two opposed rows of blocks I0, as shown in Fig. 1, beingSU-Ch that the outer ends of each adjoining pair of extensions -I2 at the contiguous ends of adjoining blocks :Iflextend under and support the inner ends of a pair of extensions I2 of'adjcining blocks at the opposite side of the wall in the nextsucceeding course with the top grooves if; of the supporting extensions 12 in matching relation with the bottom grooves I5 of the supported extensions, to accommodate at the top and bottom of each course, rods I! which insure proper alignment of the blocks of each row and proper spacing thereof from the opposite row of blocks and interlock the blocks of the two rows. These rods seat only to a depth of approximately one-half their thickness in the grooves I5 so-that as each course is laid and the rod i1 placed in the top grooves I 5 thereof, approximately onehalf of the rod projects above the top surfaces of the blocks, and by fitting the bottom grooves I5 of the next succeeding course of blocks thereon accurate location of such succeed-ing course of blocks is facilitated and insured and an interlocking of the successive courses is also provided.

Special blocks for corners, wall ends and other purposes may be provided to cooperate with the blocks It, as for example, there are shown in Fig. l inner and outer corner blocks I8 and I9 respectively for joining two wall sections at right angles to one another,'the former of which said corner blocks comprises a panel 23 with a lateral extension 2! at one endin all respects like the extensions I2 of the standard blocks l0, and at the other end the panel 20 itself is formed with grooves 22 in the top and bottom edge faces and with an end notch 23 like the grooves I5 and notches I3 respectively of the extensions I2 of the standard blocks, the length of the panel 20 being such that when the lateral extension 2| thereof is located, as shown in Fig. 1, againstthe end of the appropriate standard block of an inside row of blocks ill of one of the angular wall sections the other end of the panel 20 is suitably positioned within the other wall section to have the lateral extension I2 of an'inside block of that wall section positioned thereagainst with a pair of the rods H of the latter section engaged in the grooves 22 of the panel 2G. The outside corner block it comprises long and short panel portions 24 and 25 arranged at right angles to one another and each provided at its outer end with a lateral extension 26 in all respects like the extensions I2 of; the standard blocks, the length of the panel portions 26 and 25 being such that when located at the outside of the corner as shown in Fig. 1 the extensions 26 thereof will fit respectively agai st CQHESRQ QDI Q xt nsi ns 2. Qf s dar blocks I0 of the two angular sections of the wall. It is to be understood that in each succeeding course the arrangement of the special blocks I8 and I9 is reversed in the respect that in the courses immediately above and below the course in which the blocks I3 and I9 appear in Fig. l,

the block I8 is located as shown at 21 in Fig. l

with the lateral extension 2| thereof within the wall section at the right of the wall juncture of Fig. l and the other end of the panel 20 projecting into the other wall section whereas the outside corner block I9 in said courses above and below has the long panel portion 24 at the outer side of thewall section at the left of the wall juncture and the short panel 25 thereof in the right wall section of the Fig. 1 structure.

Fig. 4 shows .a special block 28 for wall ends which is half the length-of a standard block I0 .andhas spaced lateral extensions 2d and 30 both similar in all respects to the lateral extensions I2 of the standard blocks Ill except that the extension 39 is not provided with a notch I3 and is set back from the end of the block which is formed at that end with a thickened portion 3| having a central hump 32 at the inner side to fit in a notch I3 of a standard block. Obviously, on account of the staggered arrangement of the blocks in the inner and outer rows of each course the standard blocks of certain rows will terminate half way back from the ends of the blocks of other rows and these special blocks 28 are employed as shown in Fig. 1 to continue out to the wall end those rows wherein the blocks terminate half way back as aforesaid, the formation 3I-32 of said special blocks serving, as shown in Fig. l, to fit the notched ends of the end extensions I2 of the blocks I I of the opposed row which extend to the end of the wall. The rods I! may extend to the wall end if desired but in cases where the wall end is at a window or door opening, it is preferred to terminate the rods in the grooves of the lateral extension 36 of the half block 28 to leave therebeyond openings which are unoccupied by the rods and may be plugged or otherwise filled to receive nails or other fastenings for attaching the door or window frame to the wall end.

It will be observed that with the wall structure above described the blocks of opposed rows are entirely separated from one another except at the wall ends, thereby providing an air space between the entire inner face of each standard block and the standard blocks opposed thereto, the only connections between inner and outer standard blocks being at the top and bottom faces of the with a waterproofing and heat insulating compo' sition, which may also, if desired, be applied to the entire inner surface of the blocks or waterproof cement with heat insulating properties may be employed, either of which alternatives alone or if used together substantially prevents heat or moisture communication from either side of the wall to the other. Moreover increased heat insulation may be obtained by filling the space between the inner and outer portions of the wall with insulation material, preferably in granular, nodular or other loose form in which it may readily be poured, and the filling of this wall space is readily accomplished in view of the freely intercommunicating arrangement of all portions thereof.

The notches l3, are not essential to free lateral intercommunication throughout the wall, since the extreme ends of the extensions |2 are spaced a substantial distance from the inner faces of the opposed blocks, but these notches not only increase the intercommunioation passageways but also provide horizontally aligned openings, as indicated particularly at 33 in Fig. 7, throughout the Wall to accommodate horizontal pipes for plumbing or electric work or for other purposes as well as reinforcing rods that may be required, such piping being shown in Figs. 1, 6 and 7 with a vertical portion 34 installed between the inner and outer blocks of the wall and having a horizontal lead 35 extending laterally therefrom through the openings 33 while reinforcing rods are shown at 36 and 31 extending through said openings 33.

The blocks composing the wall may be made of any desired material and in any desired manner, preferably being molded from a material such as a cement composition and may be faced to provide any desired finish. Preferably, however, the blocks for the outside portions of walls are of waterproof concrete and the inner blocks may also be of the same material or if this is not necessary for load hearing or other purposes, the inner portion of the wall may be of cinder blocks or other light weight or porous types which may be used for both sides of inside walls unless inadequate for the loads that may be imposed thereon.

With this wall construction closed vertical chases may readily be provided at any desired place or places by providing filler blocks for continuing selected extensions |2 to the opposite side of the wall, one form of such filler block being shown at 38 which as indicated in Fig. 5 is merely a small block of suitable length and thickness to provide a continuation of a block extension I2 and has a central hump 39 to fit in the notch I3 of a standard block I0, said hump 39 being provided at opposite sides with ribs 40 to fit in the side grooves l6 of the notch l3 of the standard blocks to hold the filler block 38 against lateral displacement.

In using this block to close off a selected air space of a width corresponding to the length of a standard block, blocks 38 are applied to the ends of the extensions I2 of a block l0 at the selected location, as for example the block 4| of Fig. 1 which has filler blocks 38 at both ends thereof closing the space between said ends and the blocks at the other side of the wall, and said blocks are applied to the ends of corresponding blocks above and below the block 4| to the full length of the desired chase, it being understood that there are between such corresponding blocks intervening courses which have reversed blocks 42 at the opposite side of the wall to the ends of the extensions |2 of which filler blocks 38 are also applied to close the sides of the chase through the courses between which the blocks 4| are located. Thus a closed chase may be provided of any desired length which may be used for a hot or cold air duct or for any other purpose, for example as a form in which to pour cement to form pier members such as shown at 43 to give added strength to the wall at selected locations for supporting load bearing members thereon.

Instead of using filler blocks 38 with standard blocks I!) to provide the chases above mentioned, special blocks 44 may be provided which are the same as the standard blocks i0 except that such special blocks 44 have elongated lateral extensions 45 at the ends of sufficient length to close the space between that block and the opposite side of the wall. These blocks may be substituted for the standard blocks H3 and filler blocks 38 as indicated at 44 in Fig. l to provide vertical chases in the wall which may be used in like manner to provide hot or cold air ducts, pier forms or other purposes, the pier :33 being shown herein in association with such blocks 44 rather than the standard blocks l5 and fillers 38.

Horizontal beam members may also be readily provided at selected elevations in the wall, as for example to provide reinforcement at the floor supporting level, by closing off the bottom of a selected course of blocks and filling the space therebetween with concrete. A strip 46 of sisal kraft paper, for example, may be used for closing the bottom of the selected course, which after the course immediately below has been laid is placed over the top of that course and over the top rod I'i thereof as shown in Figs. 6 and 7 after which the next course is laid thereon and filled with concrete as shown at 47. This cement filler or beam member 4? may be reinforced by reinforcing rods 35 and 31 in the openings 33, the lower one 37 of which may rest on the bottoms of the openings 33 while the upper one 36 may be held at the top of the openings 33 in position for pouring by suspending same by wires 48 from the rod l'i immediately thereabove. Preferably if there are pier members 43 in the wall extending up to the level of the beam member 4?, the rods 3"! are bent as shown in Fig. 6 to provide portions 7 45 which extend downwardly into the chase in which the pier member 43 is located and the sisal kraft paper 46 is omitted at the top of that chase as shown in Fig. 6 so that the upper portion of the pier 43 may be poured at the same time as the beam member 4? to provide a reinforced monolithic intersection of the beam 41 and pier 43.

Any desired form of floor may be built onto the assembled block wall structure and at any selected level, an I-pan type of floor being shown in Fig. 7 wherein the inverted pans 53 are secured together in side by side relation in the usual manner with their ends projecting over the inner blocks of the course occupied by the filler 41 and after an outer block course has been laid therearound, concrete is poured over the pans 5|! as indicated at 5| to form the floor, this concrete being extended outwardly over the beam member 41' to, the outer course of blocks l3 therearound to the same level as the floor as shown in Fig. 7. Blocks 52 of half width or of other necessary width are then laid over the floor 5| to match with and bring the inner portion of the wall up to the level of the outer course around the fioor after which the wall is continued upwardly thereon in the manner of assembling hereinbefore described.

While I have shown and described my invention in a preferred form, I am aware that various changes and modifications may be made therein without departing from the principles of my invention, the scope of which is to be determined by the appended claims.

I claim as my invention:

1. The combination with a building block of the class described, comprising a relatively flat elongated panel having at one side thereof a corresponding lateral extension at each end, at least one of said extensions having a notch in the end face thereof remote from the panel of an auxiliary member having a notch fitting portion for engagement with the notched end of said extension. 7

2. The combination with a building block of the class described, comprising a relatively flat elongated panel having at one side thereof a corresponding lateral extension at each end, at least one of said extensions having a notch in the end face thereof remote from the panel of an auxiliary member having a notch fitting portion for engagement with the notched end of said extension, and means whereby the notch fitting portion of said auxiliary member is interlocked with said extension against displacement laterally therefrom.

3. The combination with a building block of the class described, comprising a relatively flat elongated panel having at one side thereof a corresponding lateral extension at each end, at least one of said extensions having a notch in the end face thereof remote from the panel of an auxiliary member having a notch fitting portion for engagement with the notched end of said extension, said auxiliary member comprising a panel with a pair of lateral extensions at one side thereof one of which said extensions of the latter panel has the aforesaid notch fitting portion at the side thereof.

4. A wall structure of the class described, comprising opposed rows of blocks at the opposite sides respectively of the wall, the blocks of each row being arranged in staggered relation to the blocks of the opposed row and having at each end thereof portions vertically commensurate therewith which extend laterally therefrom toward the blocks of the opposite row, and insert members adapted to be interposed between ends of said laterally extending portions and the blocks of the opposed row and said ends of said portions and said insert members having an interlocking engagement with one another.

5. A wall structure of the class described, comprising blocks arranged in courses each of which includes opposed rows of blocks at the inner and outer sides respectively of the wall wherein the blocks of each row are spaced throughout from and arranged in staggered relation to the blocks of the opposite row and means at the endsof selected blocks extending to the blocks opposed thereto for laterally closing a selected portion of the space between the opposed rows of blocks to provide a vertical chase within the wall.

6. A wall structure of the class described, comprising superposed courses of blocks, each course including two opposed rows of blocks and the blocks of each row having spaced upper and lower projections at their ends which extend inwardly therefrom between projections of the blocks of the opposed row and between projections of the blocks above and below said opposed row, said projections being arranged to leave a straight opening through and extending lengthwise of the course between the opposed blocks thereof, and a monolithic filler extending throughout said straight opening and localized at an elevation spaced from the top and bottom of the wall structure.

7. A wall structure of the class described, comprising superposed courses of blocks, each course including two opposed rows of blocks and the blocks of each row having spaced upper and lower projections at their ends which extend inwardly therefrom-between projections of the blocks of the opposed row and between projections of the blocks above and below said opposed row, said projections being arranged to leave a straight opening through and'extending lengthwise of the course between the opposed blocks thereof, and a monolithic filler extending throughout said straight opening and containing reinforcing members that are straddled by the upper and lower projections of the opposed blocks of said course.

8. A wall structure of the class described, comprising superposed courses of blocks, each course including two opposed rows of blocks and the blocks of each row having spaced upper and lower projections at their ends which extend inwardly therefrom between projections of the blocks of the opposed row and between projections of the blocks above and below said opposed row, said projections being arranged to leave a straight opening through and extending lengthwise of the course between the opposed blocksthereof, sheet material 'at the. bottom'of said course and a monolithic filler on said sheet material and extending throughout said straight opening.

LEONARD C. SMITH.

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