US2158982A - Building block - Google Patents

Description

16, l939 G. D. KING Er AL BUILDING BLOCK 2 Sheets-Sheet l Filed Jan. `20, 1938 G. D. KING Er AL 2,158,982

BUILDING BLOCK Filed Jan. 2o, 1938 sheets-sheet 2 May 1s, 1939.

Patented May 1.6, 1,939

' UNITED STATES Pilralirr oFFlcl-z BUILDING BLOCK Applleetlen Jennery zo, 193s, serial Ne. 185,825

` 19 claims, (ci. '12A- 41) 'I'his invention relates to a building unit and more particularly to a hollow building block adapted for use in walls and particularlyin self supporting walls ywherein the blocks are arranged to permit light to be transmitted through the wall.

'I'he invention more specifically contemplates a load supporting hollow building block comprising a shell which may have comparatively 'thick walls and open sides, and in which light transmitting facings are supported 'by the shell in a manner to close the open sides of the shell and enable light to be transmitted therethrough.

Glass masonry blocks are well known in the art l5 and provide some advantages inherent in the material used. However, they are not entirely satisfactory. They cannot be used as load bearing1 units for the reason that relatively light loads y create strains and stresses within the glass and cause it to crack, even when properly annealed.

Even under non-load-bearing conditions these blocks are stressed,.due to the weight of the block!" above, and it has been found that the addition of even a slight external force is sufdcient to cause cracking and, shattering of the already stressed glass units. A slight shock occasioned by vibration in the finished structure or by relatively weak impact may be sufcient to shatter a glass block. Also mere fluctuation in atmospheric temperature will often create a sufficient differential in expansion or contraction to cause the destruction of the glass unit. The relatively .thinner portions of the glass block, such as the side walls, do not have a uniform rate of expansion or contraction under atmospheric conditions i compared with the thicker portions, such as the corners. 'I'hus strains and stresses arev set up within the block itself, that can generally reach `equilibrium only t yby cracking, usually at the 40 corners.v f e When cracking or shattering occurs', due to one of the above mentioned causes, not only is the surface crack vunsightly in itself but it permits the ingress of moisture and dirt, which cannot be removed from the unit, and which destroys'a large percentage of the heat and sound insulating properties of the block.A Theresult is an unsightly and structurally unsound glass unit, having little of its originally intended value. Due to these defects, inherent in the structure of the fi glass block, 4its use has been 'conned Vlargely to what arel essentially window sections. Thus steel ror reinforced concretev lintels must be used over the heads of all openings containing ordinary 5s glass blocks and, 1f panels .of any consideraba size are to be employed, intermediate horizontal and vertical reinforcing is required. Such reinforcing usually takes the form of steel angle or channel sections attached to the masonry by .various means and visible on one or both sides 5 of the structure. Such reinforcing means are'unsightly and detract from the intended visible effect of solid glass masonry surfaces. It is therefore an object of the present invention to provide a light transmitting building block of the 10 character described wherein the indivdual blocks, and the Wall constructed of such blocks, may not only be self supporting, but may support the usual loads to which walls in ordinary building structures are subjected, without the necessity of em- 15 ploying external reinforcing members, and which may therefore be used in large lareas essentially as any other of the commonly employed masonry units.

A further object is the provision of a light 20 transmitting building block in which provision is made tfor a sufdcent differential in expansion and contraction of the various elements to prevent any material injury to any part of the fblock.

It is dilllcult, if not entirely impossible, to ob- 25 tain an effective bond between the ordinary glass units and conventional mortar, as no water is absorbed from the mortar,l thus greatly delaying the set. As a result the mortarAtends to ooze out unevenly from between the bloc Consequent- 30 ly the finished wall presents an uneven appearance of joints of varying width and blocks out of alignment and ay workman can lay up but a few courses per day, having then to stop work until the mortar has set. To obivate this uneven 35 settling and alignment of the glass units it has been found necessary to reinforce the horizontal mortar joints with expandetLmetal wall ties. However, even this has not satisfactorily remedied the difficulty. ofcourse, a bond may be obtained 40 by 'using special mortars containing organic materials, such as plasticized nitrated cellulose or acetylated cellulose. These mortars however are expensive andalsov harden by gradual evapora.-

tionof the solvent, consequently there is the 4,5l

same difficulty with uneven joints and slowless of erection. If agood bond is not obtained, the differential in expansion between the block and the mortar will eventua11y-cause small crevices to appear in the mortar andwill thus establish an 50 vavenue whereby moisture, either in the form ofvapor or liquid, can readily pass into the mortar joint and even through it on to the opposite side of the structure. This moisture may condenseor even freeze and* thus further promote the disruption of the bond and even cause damage to the glass unit itself.

' It is therefore another object of the present invention to provide a light transmitting building block which will overcome the above noted objections whereby the blocks may be incorporated in either a load bearing or non-load bearing wall without the necessity for reinforcement, and in which the wall and individual units therein may be substantially moisture proof.

It is also an object to provide 'an improved light transmitting building block whereby the herein noted desirable results may be obtained and serious objectionsvto prior structures avoided, as a result of an assembly comprising an improved shell structure of suitable material and characteristics in combination with various elements all of wihch are constructed and arranged to provide a block which may be conveniently assembled and which will provide suitable moisture resisting and load bearing characteristics in a iinshed wall; also the wall may present a'n attractive appearance.

It is apparent that the entrance of moisture either in the liquid or vapor phase into the' interior of a building block of the type invented would under cool conditions condense the moisture vapor present therein and form an unsightly lm within the interior of the block. For this reason it would be desirable to produce a block that has practically no moisture or water vapor within its confines. It likewise is apparent that the shell, the facings, as Well as the adjoining means,

' should be thoroughly waterproof and vaporproof to prevent the ingress of moisture or water vapor into the interior.

A still further and additional object of 'this invention is to provide a light transmitting building block used as a load bearing unit and whichv Another object is the provision of a hollowv building block having light transmitting .side panels and a load supporting shell whereby a' wall formed' of the blocks will not only enable light to be transmitted therethrough, but will also provide substantial lire resistant characteristi'cs, and wherein the wall will retain its load supporting characteristics at temperatures materially beyond the temperature at which the panels become ineiiective.`

Further objects will be apparent from the speciiication and the appended claims.

In the drawings:

Fig. 1 is a perspective view of a rectangular light transmitting building block, and illustrates one embodiment of-the invention.

Fig. 2 is a perspective View of a light transmitting building block similar to that illustrated in Fig. 1, but somewhat elongated and provided with a partition.

Fig. 3 is a transverse sectional view taken on porated.

a line substantially corresponding to line 3-3 of Fig. 1.

Fig. 4 is a diagrammatic view illustrating the blocks in position in a wall and -with mortar therebetween.

Fig. 5 is a fragmentary sectional view through one wall of a block and its adjacent light transmitting facing and illustrates one method of sup-` Fig. '7 illustrates still another method of se curing the facings in a position to cover the open sides of the block.

Fig. 8 is a perspective view of a complete block and illustrates another embodiment of the invention.

Fig. 9 is a cross sectional View through the joint between adjacent blocks such as shown in Fig. 8 when incorporated in a wall.

Fig. 10 is a transverse sectional view of one wall, of a block and illustrates a structure providing effective load bearing characteristics and reducing to a minimum the non-light-transmitting areas of the block.

Referring to the drawings in detail, the embodiment illustrated in Figs. l and 2 comprises a rectangular shell I having comparatively thick Walls and open sides as illustrated, the open sides being covered'and sealed by means of light transmitting plates or facings 3. By this construction, it will be apparent that light may be transmitted completely through the block and therefore through a wall in which the blocks are incor- The -shell I is preferably pressuremolded or otherwise formed of gypsum or a suitable cement or aggregate. It will be apparent, however, that other materials maybe used such as Portland cement, terra cotta, burnedv clay, metal, processed wood, or any other material which can be formed into block form by means of casting, casting and vibrating, pressure molding, or any other of the various methods of making building block which are well known to the art. It is preferable, however, that the material used should be of such a nature as to provide a unit capable ofsupporting a substantial load and capable of bonding effectively with conventional mortars.

4Pressure molding is very .desirable to provide increased density and moisture resistance. Also great strength may be obtained in a shell having comparatively thin walls, thus reducing the *non-light-transinittingv areas in the finished wall.

When it is desired to provide additional strength in the walls of the block, this may be obtained by using a suitable reinforcing means 4 such as expanded metal, which may be embedded in the walls of the block.

The material of, vwhich the shell -is made may provide suitable moisture proof characteristics, that is, suitable waterproofing material may be mixed with the base material from which the block is formed so that, after the block is pressure-molded or otherwise suitably formed, the material thereof is inherently water and water vapor proof. Under some circumstances it is preferable to use the usual materials such as previously` mentioned to form the shell and then .treat or coat the entire inner and outer surfaces of the shell with suitable waterproong mate-A rial to prevent moisture and water vapor infiltration.

The light transmitting facings 3 may be secured in position by vsuitable adhesive (Figs. 2 and 4) applied between the facings and the-walls of the shell. This adhesive 571s preferably a yieldable material such as an asphalt adhesive and therefore permitsl a differential contraction,

and expansion of the shell and facings in response to temperature changes.

vIn the embodiment illustrated in detail in Fig. 3, the outer surface of the shell may be provided with a moisture and water vapor'proof coating 6 and the facings may be secured to the walls by means ofa layer of adhesive 1 therebetween.

' This adhesive may be of material similar to the coating or of any suitable material, such as the adhesive 5, whereby the relative expansion .and contraction of the parts may take place without injury to the blocks. The plaster between the blocks is shown at 8 in Fig. 4. The entire surface of the shell or any desired portions thereof,

such as the inside surface, may be treated with space is maintained.

A thin light-reflecting metallic foil or coating 3 may be applied to the inner surface of the shell as shown in Fig. 3.. This provides some heat insulation and efficient moisture and water vapor proofing. The aluminum foilon the interior of the block has a marked tendency to increase the reflection of the light and therefore produces an optical illusion of an all glass section which approaches glass block in apparent characteristics.

Such a coating may also be applied to the outer surface of the sneu if desired. A suitable method I of moisture and water vapor-proofing the shell is to impregnate the building unit by immersion in the water and vapor proofing material either under pressure or vacuum. In any event it is desirable to water and vapor proof the unit sufiiciently to prevent ingress of moisture to the'interior, either at the facings or through the shell. The facings 3 are preferably made of glass, although various transparent or translucent materials may be used, such ascertain resins, gelatin films, etc., which are capable of withstanding varying atmospheric conditions. The facings may be decorated as desired, or may be of any suitable color, andv if desired they may be reinforced with some material as wire'mesh to give increased fire protection. j

In securing the facings Sto the block, it ,is desired to provide a suitable moisture -and vapor proof seal and at the same time permit relative expansion and contraction of the ,elements of the unit. -Inbrde'r to accomplish this, the ends of the walls to which the facings are to be applied may be coated with suitable adhesive, preferably an asphalt adhesive, and the facings may be applied thereto by pressure. It is also desirable to protect the adhesive from the disintegrating effects of light rays. The engaging marginal por,- tions of the facings may therefore be'coated with some opaque materials such as aluminum paint or may have foil applied thereto to provide an opaque film III betweenthe facing and the shell. 'I'his film III may 'provide alight reflecting surface adjacent thefacing, if desired, to reduce .the contrast between the center 4of thebiock and the shell wallsas showninFlg.1.

It will be apparent that the construction just ldescribed will provide a load bearing and light transmitting moisture proof block which will not be materially affected by temperature changes nor by any of the usual strains and stresses to which they are ordinarily subjected.

In Fig. 2 the shell Ia is elongated or may be made in any desired shape, and is'provided with a central partition II to provide additional'l strength for the load supporting function of the block. The light transmitting facings 3a may cover the entire face of the block in the same manner as illustrated in Fig. 1. g

' Fig. 5 illustrates a somewhat different method vof securing the facingsv to the shell. 'In this embodiment the walls of the shell are provided with 'channels I2 having a suitable plastic material I3 therein, and light transmitting facings I4 may be provided with inturned flanges I5.

,These flanges I5 are pressed into the plastic material as-illustrated and are therefore retained in place and the joint between the facing and shell is eiectively sealed. The plastic material I3 enables relative expansion and contraction'of the block and facings.

Fig. 6 illustrates another embodiment of the invention'in whichl facings I6 are provided with suitable holes I1 therethrough and the walls are provided with spaced expansion sockets I8, which are embedded therein. Screws or bolts I9 may be inserted through the holes in'the facings and secured in the sockets I8. A suitable adhesive 2li is provided between thefacings and the shell,

. and the facings may securely be clamped by means of the screws I9. This provides 'an effective moisture and, water vapor proofing between the facings and-the shell 'and the holes I1 permit relative expansion and contraction of the parts. Figl illustrates still another method of securing the facings in aposition to cover the open sides of the block. In this embodiment a metallic covering 2| preferably of sheet metal is provided for the shell I and this covering extends somewhat beyond the edges of the shell as shown and is provided with downwardly extending flanges 22 and 23. 'I'he flange 23 'is formed after lthe facing is inserted by rolling or pressing the material of the covering downwardlyV over the illustrated in Fig. 4, in which they are secured together by means of the layer 8 or mortar between the units.

Figs. 8 and 9 illustrate an embodiment o'f the invention wherein the walls-of the shell are formed to provide. a depression or channel 25 between adjacent blocks and to enable the edges" of the blocks to contact at 26 (Fig. 9). The depression provides a pocket to receive the mortar 21. The facings 3a are of slightly smaller dimensions than the block to.prevent any portion of the load from the wall above from being transmitted to the facings themselvea After erection of the wall the joints between the facings may be pointed up as shown at 28 with neat Portland cement or other suitable plastic material. In this construction the visiblemortar joint between the facings is reduced to a minimum and the -wall presents a morenearly solid glass surface.

' In Fig. 10 the walls of the shell are of a miniareas of the block. 'I'he wall may be curved inwardly, or otherwise'formed in a manner to give the required thickness at the center for load bearing strength and at the same time provide a reflecting surface 'at 29 which will not ,he visible from the exterior'of the block. The facings may be secured to the block in a suitable manner as previously described. In the embodiment shown, clips 30 are arranged to engage'over the edge of the facing and are provided with inwardly eX- tending portions secured Ain the shell. A layer of suitable yielding adhesive 32 may be used to seal the joint between the facing and shell.

It will be apparent that, with any of the embodiments herein illustrated and described, it is possible to easily remove and replace any individual facing of a block even after the block has been installed in a wall. This is very desirable in the event that repairs are required and also when it is desired to change the facings in order to vary the decorative features of the structure.

-Avwall'constructed of units made in accordance with this' invention enables light to be transmitted to the interior of the building and, in

addition, the Walls are load supporting and provide effective heat land sound insulation and are The shell provides sufiicient`- -of molded material and having open sides, a light transmitting'facing covering each open side, a layer of plastic adhesive between said facings and said shell walls, and an opaque coating secured to the inner marginal surface of said facings for preventing light transmission to said plastic adhesive.

2. A hollow building block' comprising a shell lof molded material and having open sides, a

light transmitting facing covering each open side and substantially coextensive therewith, a layer of plastic adhesive between said facings and said walls, and-a moisture and vapor proof coating on the outer surfaces of said shell, said coating overlapping the edges of said facings and having ef 'i fective bonding characteristics with conventional y mortar.

3. In a hollow building block of the character described, a cementitious shell, a light transmitting element covering an open side of said shell and means whereby the inner marginal surface of said element overlapping the wallsof said shell i will reflect light outwardly therefrom.

,4. A hollow building block comprising a shell .having open sides, the walls of said shell having between the open sides whereby themarginal edges of adjacent blocks in a Wall may be contiguous, and a comparatively thin, light transmitting facing covering each ,open side and of smaller dimensions than the adjacent open sides of said shell to provide a. narrow pointing groove between the edges of the facings of adjacentv blocks.

6. A hollow building block comprising a shell having open sides and having itsouter surface arranged to form a plaster pocket between adjacent blocks in a wall with the outer edges of said outer surfaces'substantially in load supporting contact, and a glass plate covering each open side and of smaller dimensions than said block to provide a narrowgroove between the edges of the facings of adjacent contacting blocks.

7. A light transmitting hollow building block comprising a molded opaque shell having open sides, light transmitting facings covering said open sides and substantially coextensive therewith, the inner surface of the walls of saidfshell being substantially convex to provide a thick intermediate load bearing portion, and being materially thinner adjacent the facings whereby the non-light-transmitting area of the block is rer duced to a minimum, and a reenforcing web embedded in said walls and extending closely adjacent the `edges thereof to reenforce the thin portions of the walls'.

8. A light transmitting hollow building block comprising a molded -opaque shell having open sides, light transmitting facings covering said open sides, the walls of said shell in cross section having a thick intermediate load bearing portion, and being materially thinner adjacent the facings whereby the non-light-transmitting area ofthe block is reduced to a'minifrim, the shell having a lightreflecting inner surface, and means whereby the inner marginal surface of said facings overlapping said walls will reflect light outwardly therefrom.

9. In a block of the character described com. prising a molded hollow shell having open sides and glass plates covering said opensides, means for securing said plates, said means comprising a socket secured into said shell, means extending through an opening in said plate and engaging in said socket, said opening being of a size to permit relative movement ofadjacent surfaces dueto temperature changes, and a yielding adhesive between said plates and said shell.

10. A hollow building unit comprising a, load supporting and moisture and water vapor proof integral shell having open sides, a light transmitting facing attached to each open side of said shell, a moisture and water'vapor proof seal between said facingand said shell, and means for securing said facing, said securing means comprising clips molded into said shell and engaging the edges of ,said facing.

1l. A hollow building block comprising a load supporting. shell of preformed Amaterialhaving open sides, a light pervious -facing covering each 'lopen side and overlapping-the walls of said shell, a layer of. plastic adhesive between said facings land said sh'ell, and an opaque coating secured to the inner marginal surface of said facings-and substantially coextensive with said adhesive, said coating having a light reflecting surface.adjacent said facings. A s

12. A hollow building block comprising a load supporting shell of molded material having open sides, a light pervious facing secured to and covering each open side of said block and substantially coextensive therewith, and a thin layer of material between 'the walls of said block andthe inner marginal surfaces of said facings and coextensive with the wall surfaces covered by said faclngs, the outer surface of said layer beingl light reflecting.

13'. A hollow building block' comprising a load supporting shell of molded material having open sides, a light pervious facing secured to and covering each open side of said block and substantially coextensive therewith, and a thin layer of material between the walls of said block and the inner marginal surfaces of said facings and coextensive with the wall surfaces 'covered by said facings', the entire inner surface of said block and the outer surface of said layer being light reilectlng. v

14. A hollow building block4 comprising a load supporting shell of molded material having open sides, alight pervious facing secured to and cov- -erlng each open side and overlapping the walls thereof and substantially coextensive therewith,

a layer of light reectingmaterial between said7 ing its inner surfaces rendered substantially impermeable to moisture and water vapor, light'- transmitting fscings verlng the open nda of said shell, means for securing said facings to said shell, and means for 'providing a substantially moisture and water vapor impermeable joint between said facing and said shell.

16. A hollow building block comprising a shell of molded material and having open sides. s light- '.transmittlngrscing covering each cpm dds,

means for securing said facings to said shell,and

- a highly light-reflecting metallic nlm on the inand an illusion is thus given of anall-glass block.

17. A hollow building block comprising a shellA of molded material and having open sides,a lightbeing supported aidistance away. from the edge' surfaces of the shell bymeans of relatively thin supporting means. whereby the opaque shell edges are 19. A hollow building block comprising a shell composed of cement molded under pressure, said shell having open sides and the walls thereof bi ofv sumcient thickness to provide a selfsupporting wall when the blocks are assembled, the outer cement surface of said vshell retaining its porosity and suction so that it has effective bonding characteristics with conventional cementitious mortal-s. said shell having its inner surfaces rendered' substantially impermeable. to moisture and water vapor, light-transmitting faclngs covering the open sides of said shell, means for securing said facings, to said shell, and means for providing s substantially moisture and vapor impermeable joint between said facings and said GEORGE D. KING. GEORGE L PHELPS.

not readily discernible through the glass AI. l v v

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