Canadian Patents Database / Patent 2696981 Summary

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(12) Patent Application: (11) CA 2696981
(54) English Title: BUILDING BLOCK SYSTEM
(54) French Title: SYSTEME DE BLOCS DE CONSTRUCTION
(51) International Patent Classification (IPC):
  • E04C 1/00 (2006.01)
  • E02D 29/02 (2006.01)
  • E04B 2/18 (2006.01)
  • E04B 2/22 (2006.01)
(72) Inventors :
  • BOOT, DANIEL A.L. (Canada)
(73) Owners :
  • HABITERRA BUILDING SOLUTIONS INC. (Canada)
(71) Applicants :
  • HABITERRA BUILDING SOLUTIONS INC. (Canada)
(74) Agent: OYEN WIGGS GREEN & MUTALA LLP
(74) Associate agent:
(45) Issued:
(86) PCT Filing Date: 2007-06-11
(87) Open to Public Inspection: 2008-12-18
Examination requested: 2012-06-04
(30) Availability of licence: N/A
(30) Language of filing: English

English Abstract




An interlocking concrete block for forming horizontal wall- channels for
reinforcement of block walls of dry-stack,
vertically-offset, double-wythe construction. The block has an outer block
wall on one side and a head portion extending to the
opposed side. The head portion has a connecting portion which interfits with a
receptacle of a similar block. The block has a channel
extending generally parallel to the outer block wall. In a block wall, two
vertically-adjacent series of the blocks form a horizontal
wall channel which can hold a reinforcing bar and in-filled concrete, for
horizontal reinforcement of the wall.




French Abstract

L'invention concerne un bloc de béton s'interverrouillant pour former des rainures de paroi horizontales pour le renforcement des parois de bloc d'une construction sèche à double languette, décalée verticalement. Le bloc possède une paroi de bloc externe sur un côté et une partie de tête s'étendant vers le côté opposé. La partie de tête a une partie de raccordement qui s'adapte avec un logement d'un bloc similaire. Le bloc possède une rainure s'étendant généralement de façon parallèle à la paroi de bloc externe. Dans une paroi de bloc, deux séries verticalement adjacentes de blocs forment une rainure de paroi horizontale qui peut supporter une barre de renforcement et du béton versé dans celle-ci pour un renforcement horizontal de la paroi.


Note: Claims are shown in the official language in which they were submitted.



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WHAT IS CLAIMED IS:


1. A block (10) for use in interlocking with other similar
blocks to form a substantially horizontal channel (52) in a building
wall (54), the block comprising:

a top surface (12);

a bottom surface (14);

an outer block wall (16) defining a first side surface (17) of
the block;

an interlocking section for attachment to the interlocking
section of a cooperating interlocking block whose first side surface
is opposite to the first side surface of the block (10);

a channel (26) open to the block top surface (12) extending
generally parallel to the outer block wall and having opposed first
and second channel side walls (28, 30) and a channel bottom wall
(32);

the interlocking section defining a flange (15) spaced from
the outer block wall (16) extending to the top surface (12) of the
block;

the channel (26) being configured to receive the flange (15)
of the cooperating interlocking block.



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2. A block (10) for use in interlocking with other similar
blocks to form a substantially horizontal channel (52) in a building
wall (54), the block comprising:

a top surface (12);

a bottom surface (14);

an outer block wall (16) defining a first side surface (17) of
the block;

a head portion (18) extending from the outer block wall
towards an opposed, second side surface (20), the head portion
defining at least one connecting portion (22);

at least one receptacle (24) substantially matching in shape
the connecting portion (22) for receiving in interlocking
relationship the connecting portion of a cooperating interlocking
block whose first side surface is opposite to the first side surface
(17) of the block (10);

a channel (26) open to the block top surface (12) extending
generally parallel to the outer block wall (16) and having opposed
first and second channel side walls (28, 30) and a channel bottom
wall (32);

the head portion (18) further defining a flange (15) at the
second side surface (20) of the block (10), the flange (15)
extending between the second channel side wall (30) and the



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second side surface (20) of the block (10) and to the top surface
(12) of the block (10);

the channel (26) being sized and configured to receive the
flange (15) of the cooperating interlocking block.


3. A block according to claim 2, wherein there are two
connecting portions (22) each on a respective side of the head
portion, and wherein the block (10) further comprises:

two abutment portions (36) each at a respective end of the
outer block wall and each defining a respective abutment shoulder
(38);

a central groove (40) in the head portion at a position
thereon opposite to the outer block wall (16), the groove at
opposite ends thereof defining two inwardly facing shoulders (42)
each for engaging and retaining the abutment portion of a
respective one of two abutting blocks such that the abutment
portions (36) are retained end to end within the central groove
(40); and

wherein there are two receptacles (24), each defined
between a respective abutment portion and connecting portion
(22).


4. A block (10) according to any one of claims 1 to 3, wherein
the channel (26) is configured such that the top surface (12) of the



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flange (15) of the cooperating interlocking block abuts the channel
bottom wall (32) of the block (10).


5. A block according to any one of claims 1 to 4, wherein the
block defines a hole (34) extending therethrough generally
perpendicular to the block bottom surface (14).


6. A block according to any one of claims 1 to 5, wherein the
first side surface (17) of the block has a height that is equal to a
height of the second side surface (20).


7. A block according to any one of claims 1 to 6, wherein the
channel bottom wall (32) is spaced from the block bottom surface
(14) by a distance that is greater than the distance between the
channel bottom wall and the block top surface (12).


8. A building wall (54) comprising a plurality of interlocking
blocks, each block (10) comprising: a top surface (12); a bottom
surface (14); an outer block wall (16) defining a first side surface
(17) of the block; a head portion (18) extending from the outer
block wall (16) toward an opposed, second side surface (20); a
connecting portion (22) on the head portion; two abutment
portions (36) each at a respective end of the outer block wall (16);
a receptacle (24) substantially matching in shape the connecting
portion (22); a channel (26) open to the block top surface (12)
extending substantially parallel to the outer block wall (16) and
having opposed first and second channel side walls (28, 30) and a
channel bottom wall (32); a flange (15) at the second side surface
(20) of the block (10), the flange extending between the second


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channel side wall (30) and the second side surface (20) of the
block (10) and to the top surface (12) of the block (10);


the blocks (10) being arranged to define a first series (44) of
the blocks (10) in which the first side surface (17) of each of the
first series of blocks is arranged to form a first vertical side
surface (46) of the wall, and a second series (48) of the blocks
(10) in which the first side surface (17) of each of the second
series of blocks is arranged to form a second vertical side surface
(50) of the wall opposite to the first vertical side surface (46);


the blocks (10) being interlocked such that: two abutment
portions (36) each of a respective one of two adjacent blocks of
the second series (48) are positioned end to end; two abutment
portions each of a respective one of two adjacent blocks of the
first series are positioned end to end ; the receptacle (24) of each
block of the first series of blocks receives in interlocking
relationship a respective connecting portion (22) of a block of the
second series of blocks; the receptacle (24) of each block of the
second series of blocks receives in interlocking relationship a
respective connecting portion (22) of a block of the first series of
blocks; the channel bottom wall (32) of each of the blocks of the
first series (44) is spaced from and opposite to the channel bottom
wall (32) of a block of the second series of blocks; and the flanges
(15) of the blocks of each of the two series (44, 48) are received
in the channels (26) of blocks of the respective other series, with
the top surface (12) of the flanges (15) of each of the blocks
abutting the channel bottom wall (32) of the blocks of the
respective other series; and the channels (26) of the blocks of the


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first series and of the second series together forming a wall
channel (52) extending generally horizontally in the building wall
(54).


9. A building wall (54) according to claim 8, wherein each of
the blocks (10) further comprises: two said connecting portions
(22), each on a respective side of the head portion, each of the
abutment portions (36) defining a respective abutment shoulder
(38) on a face of the outer block wall opposite to the first side
surface (17) thereof; two said receptacles (24) each arranged
between a respective one of the abutment portions (36) and a
respective one of the connecting portions (22); a central groove
(40) in the head portion at a position thereon opposite to the outer
block wall, the groove at opposite ends thereof defining two
inwardly facing opposed shoulders (42);


wherein the blocks are interlocked such that: two abutment
portions (36) each of a respective one of two adjacent blocks of
the second series (48) fit into the central groove (40) in an
opposed one of the blocks of the first series (44) such that the
abutment portions are retained end to end within the central
groove; two abutment portions each of a respective one of two
adjacent blocks of the first series fit into the single central groove
in an opposed one of the blocks of the second series such that the
abutment portions are retained end to end within the single
groove; each receptacle (24) of each of the first series of blocks
receives in interlocking relationship a respective one of the
connecting portions (22) of the second series of blocks; each
receptacle of each of the second series of blocks receives in


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interlocking relationship a respective one of the connecting
portions (22) of the first series of blocks.


10. A building wall according to claim 8 or 9, further
comprising a reinforcing member (58) extending through the wall
channel (52).


11. A building wall according to claim 10, further comprising
mortar in said wall channel (52).

Note: Descriptions are shown in the official language in which they were submitted.


CA 02696981 2009-12-09
WO 2008/151403 PCT/CA2007/001017

BUILDING BLOCK SYSTEM
Field of the Invention

This invention pertains to interlocking blocks for use in construct-
ing buildings and the like. More particularly, it pertains to interlocking
blocks that form horizontal channels in a building wall. The channels
can be used for reinforcement of the wall.

Background of the Invention

It is known in the art of building with concrete blocks to make
double-wythe walls which comprise two vertically-offset series of
blocks, one series of which forms one wall face and the second series of
which interlocks with the first series and forms the opposed wall face.
US 6,508,041 Boot and US 4,704,832 Vassiliadis show examples of
this type of wall system. It is used in the dry-stack construction of load-
bearing and non-load-bearing walls.

Walls made using these systems can be reinforced by vertical
members but they do not provide for horizontal means of reinforce-
ment, which limits their strength and stability.

Summary of the Invention
The invention provides a form of block for vertically-offset
double-wythe wall construction, which blocks are arranged to form
generally horizontal wall channels. The wall channels can accommo-
date reinforcing members and concrete in-fill for the purpose of rein-
forcing the block walls. Buildings made with such horizontal reinforce-
ment are considerably stronger than buildings made using prior art
block systems lacking such reinforcement.


CA 02696981 2009-12-09
WO 2008/151403 PCT/CA2007/001017
-2-
In general terms, the block has an outer block wall that defines a first
side surface of the block and an interlocking section for attachment to
the interlocking section of a cooperating interlocking block whose first
side surface is opposite to the first side surface of the block, and a
channel that is open to the top surface of the block.

The invention provides a block comprising an outer block wall on
one side of the block and a head portion extending towards the opposed
side surface of the block. The head portion has a connecting portion
which interfits with a receptacle of a similar cooperating block that is
positioned with its outer block wall opposite to that of the first block.
The block has a channel extending generally parallel to the outer block
wall.

The invention further provides a building wall which includes
such blocks arranged so as to form a horizontal wall channel.
According to one preferred embodiment of the invention, there is
provided a block for use in interlocking with similar blocks in forming a
substantially horizontal channel in a building wall. The block comprises
a top surface, a bottom surface, an outer block wall defining a first side
surface of the block and a head portion extending from the outer block
wall towards an opposed, second side surface. The head portion defines
at least one connecting portion. The block has at least one receptacle
substantially matching in shape the connecting portion for receiving in
interlocking relationship the connecting portion of a cooperating inter-
locking block whose first side surface is opposite to the first side surface
of the block. The block has a channel open to the block top surface
extending generally parallel to the outer block wall and having two
opposed channel side walls and a channel bottom wall.


CA 02696981 2009-12-09
WO 2008/151403 PCT/CA2007/001017
-3-
According to another preferred embodiment of the invention, there
is provided a block for use in interlocking with other similar blocks in
forming a substantially horizontal channel in a building wall, which
block comprises a top surface, a bottom surface, an outer block wall
defining a first side surface of the block, and a head portion extending
from the outer block wall toward an opposed, second side surface. The
block has two connecting portions each on a respective side of the head
portion. The block has two abutment portions each at a respective end
of the outer block wall and each defining a respective abutment shoulder.
There is a central groove in the head portion at a position thereon
opposite to the outer block wall, the groove at opposite ends thereof
defining two inwardly facing shoulders each for engaging and retaining
the abutment portion of a respective one of two abutting blocks such that
the abutment portions are retained end to end within the central groove.
There is defined between the abutment portion and the connecting
portion a receptacle substantially matching in shape the connecting
portion for receiving in interlocking relationship the connecting portion
of a cooperating interlocking block. The block defines a channel open to
the block top surface extending substantially parallel to the outer block
wall and having two opposed channel side walls and a channel bottom
wall.

Brief Description of the Drawin!s

In drawings which illustrate an exemplary embodiment of the
invention:

Fig. 1 is a top perspective view of a block according to one
embodiment of the invention;
Fig. 2 is a bottom perspective view of the block of Fig. 1;


CA 02696981 2009-12-09
WO 2008/151403 PCT/CA2007/001017
-4-
Fig. 3 is a top plan view of the block of Fig. 1;

Fig. 4 is an end view of the block of Fig. 1;

Fig. 5 is a top plan view of three interlocking blocks;
Fig. 6 is a cross-sectional view on the line 6-6 of Fig. 5;

Fig. 7 is a perspective view of a portion of a building wall having
two series of the blocks of Fig. 1 forming a horizontal wall channel; and
Figs. 8 and 9 are a perspective and plan view respectively of a
prior art block.

Detailed Description of the Preferred Embodiments

Referring to Figs. 1 to 4, which illustrate an exemplary embodi-
ment of the invention, the block 10 has a top surface 12, a bottom
surface 14, an outer wall 16 and a head portion 18. The block outer
wall 16 defines one side surface 17 of the block. The head portion 18
extends to the opposed, second side surface 20. The head portion has a
lobe-shaped connecting portion 22 on each side thereof. The outer block
wall 16 has an abutment portion 36 at each end thereof, each defining an
abutment shoulder 38. Two concave receptacles 24, each between a
respective connecting portion 22 and abutment shoulder 38, have a shape
corresponding to that of a connecting portion 22 and are sized to receive
a connecting portion 22 of a second block in interlocking relationship
therewith. The head portion 18 has a central groove 40 at a position
opposite to the outer block wall 16. The groove 40 defines two shoul-
ders 42 which engage the abutment portions 36 of two abutting interlock-
ing blocks.


PCT/CA2007/001017
CA 02696981 2009-12-09 05 June 2008 05-06-2008
-5-

A channe126 in the block is open to the top surface 12 of the
block and has opposed side walls 28, 30 and a bottom wall 32. The
channel 26 extends generally parallel to the outer block wall 16. The
channel bottom wall 32 is spaced from the bottom surface 14 by a
distance that is greater than the distance between the channel bottom wall
and the top surface 12, as explained below.

The head portion 18 defines a flange 15 extending between the
"` channel side wall 30 and the second side surface 20 of the block and to
the top surface 12 of the block.

A hole 34 extends through the block from the top surface to the
bottom surface.
Figs. 8 and 9 illustrate a prior art block lOP as disclosed in US
6,508,041 Boot. The shape and size of the block 10 is such that it
interlocks with the prior art block lOP, which prior art block is similar
to the block 10 but it does not have any channel. In the illustration of
the prior art block lOP in Figs. 8 and 9, corresponding and like elements
to those of the block 10 are indicated by the same reference numerals.
When used in the construction of a wall, the blocks 10 are in-
tended to be used in forming horizontal channels at selected heights, for
example at a height of four feet in an eight-foot high wall. The blocks
10 are not intended for construction of the entire wall, as horizontal wall
channels at every course are not necessary. It is intended that the
remainder of the wall below and above such wall channel would be
constructed using the prior art blocks lOP.

AMENDED SHEET


PCT/CA2007/001017
CA 02696981 2009-12-09 05 June 2008 05-06-2008
6-

In constructing a double-wythe wall using the blocks 10 and the
prior art blocks lOP, a first course of prior art blocks lOP is made on a
suitable footing along the perimeter of the structure. To do this, a series
of the prior art blocks lOP is placed at the external side of the wall to
begin the external wythe and a series of half height blocks (identical to
blocks lOP except one half the height) is placed at the internal side of the
wall to begin the internal wythe, interlocking with the blocks of the first
series. After this first course, all subsequent courses consist of full
height units (except where levelled at window sills and at the wall top,
where half height blocks are used). The external series and the internal
series of blocks are always offset from each other by one half of a block
height as a result of placing half height blocks in the first course.

Figs. 5-7 show the blocks 10 interfitting with like blocks. As best
seen in Fig. 7, at a selected height in the construction of a wall, say four
feet, the blocks 10 of the present invention are employed to form a
channel for horizontal reinforcement of the wall. A first series 44 of the
blocks 10 is laid to interlock with the uppermost course of the prior art
blocks lOP. This series 44 of blocks 10 is laid with the channels 26
facing upward. The connecting portions 22 of the uppermost course of
the prior art blocks lOP are received in the respective receptacles 24 of
the blocks 10, and the abutment portions 36 of the abutting blocks 10 are
fitted in respective central grooves 40 of the prior art blocks lOP.

Before placing a reinforcing bar 58 in the horizontally-extending
space formed by the channels 26 of the series 44 of blocks 10, the holes
34 in the prior art blocks lOP and in the blocks 10 that will lie under the
reinforcing bar are plugged sufficiently to retain the concrete that is later
in-filled around the bar. The plugging can be done, for example, using
AMENDED SHEET


PCT/CA2007/001017
CA 02696981 2009-12-09 05 June 2008 05-06-2008
-7-

crushed sheets of newspaper. Any holes 34 that will be used for vertical
reinforcing bars 60 and in-filling of concrete are not plugged.

A reinforcing bar 58 is then placed in the horizontally-extending
space formed by the channels 26, resting on the bottom wall 32 of the
channels 26. It will be apparent that, because the channel bottom wall
32 is higher than the vertical midpoint of the block, the channel bottom
wall 32 of the blocks 10 is higher than the top surface 12 of the upper-
most course of prior art blocks lOP, so the reinforcing bar 58 does not
rest on such top surface 12 but is supported only by the relatively narrow
parts of the channel bottom wall that are on either side of the hole 34.
This feature permits the concrete which is filled into the wall channel, as
discussed below, to more completely surround the reinforcing bar and
therefore to better bond to it.
The horizontal reinforcing bars 58 are adjacent to the vertical
reinforcing bars 60 that are positioned in holes 34 at selected spacing
(for example 120 cm spacing) and can be affixed thereto by means of
twisted wire or the like.
After the reinforcing bar 58 is laid in position, a second series 48
of the blocks 10 is laid in interlocking arrangement with the first series
44 to form the wall channel 52. The second series is placed with the
channels 26 facing downward. The connecting portions 22 of the blocks
10 of the second series 48 are received in the respective receptacles 24
of the blocks 10 of the first series 44, and the abutment portions 36 of
abutting blocks 10 of the second series 48 are fitted in respective central
grooves 40 of the blocks 10 of the first series 44. The top surface 12 of
the blocks of the second series 48 faces downward and abuts the top

AMENDED SHEET


PCT/CA2007/001017
CA 02696981 2009-12-09 05 June 2008 05-06-2008
8-

surface 12 of the uppermost course of the prior art blocks lOP. The
channel bottom wall 32 of the blocks of the second series 48 is accord-
ingly spaced from and opposed to the channel bottom wall 32 of the
blocks of the first series 44, and the channels 26 of the blocks of the first
and second series collectively form a wall channel 52 extending gener-
ally horizontally through the wall. As best seen in Fig. 6, the flanges 15
of the blocks of each of the series 44, 48 are received in the channels 26
of the blocks of the respective other series, with the top surface 12 of the
flanges abutting the channel bottom wall 32 of the blocks of the respec-
tive other series. It will be noted that the channel 26 in each block 10 is
sufficiently wide and is so positioned relative to the width of the block
that the channels 26 of the blocks of one series overlap in longitudinal
extension with those of the second series so that a continuous passage-
way through the wall, i.e. wall channel 52, is formed by the block
channels 26.

At this point in the construction of the wall, concrete is in-filled
into the wall channel 52 through the holes 34 in the blocks 10 of the
second series 48, and into selected vertical channels (i.e. the channels
comprising aligned holes 34 in vertically positioned blocks 10 and lOP).
Once the concrete has set, construction of the wall continues with a
series of prior art blocks lOP fitted to the second series 48 of the blocks
10, and so on to the desired wall height.

It will be apparent that the first side surface 17 of the blocks 10 of
the first series 44 forms part of one vertical side surface 46 of the
building wall 54, and the first side surface 17 of the blocks 10 of the
second series 48 forms part of the second, opposed vertical side surface
50 of the wall. These parts are continuous with the respective side

AMENDED SHEET


PCT/CA2007/001017
CA 02696981 2009-12-09 05 June 2008 05-06-2008
9-

surfaces of the wall formed by the prior art blocks lOP that are below
and above the first and second series 44, 48 of the blocks 10.

Walls and buildings constructed using the blocks 10 can include
end blocks for ending a wall and corner blocks for making corners in
walls, as described in US 6,508,041 Boot.

The block 10 of the invention is made of concrete, or alternatively
of clay or other suitable material. It is nominally 40 cm long, 20 cm
high and 15 cm wide.

Apart from the use of concrete in the horizontal wall channels and
in selected vertical channels, concrete is not used in the building of the
walls as the construction is dry-stack type, the blocks not being mortared
in place.

Although the invention has been described in terms of specific
embodiments, it is not intended that the invention is limited to those
embodiments. Various modifications within the scope of the invention
will be apparent to those skilled in the art. The scope of the invention is
defined by the claims that follow.

AMENDED SHEET

A single figure which represents the drawing illustrating the invention.

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Admin Status

Title Date
Forecasted Issue Date Unavailable
(86) PCT Filing Date 2007-06-11
(87) PCT Publication Date 2008-12-18
(85) National Entry 2009-12-09
Examination Requested 2012-06-04
Dead Application 2015-03-12

Abandonment History

Abandonment Date Reason Reinstatement Date
2009-06-11 FAILURE TO PAY APPLICATION MAINTENANCE FEE 2010-06-09
2014-03-12 FAILURE TO PAY FINAL FEE
2014-06-11 FAILURE TO PAY APPLICATION MAINTENANCE FEE

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $200.00 2009-12-09
Reinstatement: Failure to Pay Application Maintenance Fees $200.00 2010-06-09
Maintenance Fee - Application - New Act 2 2009-06-11 $50.00 2010-06-09
Maintenance Fee - Application - New Act 3 2010-06-11 $50.00 2010-06-09
Reinstatement of rights $200.00 2010-07-16
Maintenance Fee - Application - New Act 4 2011-06-13 $50.00 2011-06-10
Maintenance Fee - Application - New Act 5 2012-06-11 $100.00 2012-05-11
Request for Examination $100.00 2012-06-04
Maintenance Fee - Application - New Act 6 2013-06-11 $100.00 2013-04-16
Current owners on record shown in alphabetical order.
Current Owners on Record
HABITERRA BUILDING SOLUTIONS INC.
Past owners on record shown in alphabetical order.
Past Owners on Record
BOOT, DANIEL A.L.
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.

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Document
Description
Date
(yyyy-mm-dd)
Number of pages Size of Image (KB)
Abstract 2009-12-09 2 64
Claims 2009-12-09 7 232
Drawings 2009-12-09 4 84
Description 2009-12-09 9 391
Representative Drawing 2009-12-09 1 12
Cover Page 2010-05-05 2 44
PCT 2009-12-09 21 798
Assignment 2009-12-09 3 106
Correspondence 2010-04-26 1 23
Fees 2010-06-09 5 322
Correspondence 2010-07-16 3 94
Correspondence 2010-08-17 1 19
Correspondence 2010-08-17 1 16
Prosecution-Amendment 2012-06-04 1 38