Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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Reusable Modular Block Wall Assembly System
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates generally to a building system.
Particularly,
the present invention relates to a building system with individual building
components
connected together.
2. Description of the Prior Art
[0002] The art of constructing buildings or enclosures to protect people and
things
from the weather has been done throughout the ages. Building systems and
methods have been devised to accomplish the assembly of buildings in a more
orderly and predetermined fashion using a variety of building materials.
[0003] The most commonly used method in both residential and commercial wall
construction is known as stick-built construction. Stick-built construction is
relatively
slow, requiring numerous types of materials and steps to complete the assembly
process. It is relatively low technology and typically does not require
special or large
equipment for installation. A typical wall system in a commercial assembly
requires
at least four and as many as seven trades. Stick-built construction is seldom
successful in achieving high-performance structures as the high number of
parts,
steps, and trades generally leads to problems with air barrier and insulation
performance. Further, stick-built construction is never reusable.
[0004] Another method used is known as prefabricated and/or panelized
construction. In this method, some of the construction steps of the stick-
built method
are performed in a factory and then the components are shipped to the site in
the
form of larger, pre-assembled units. Prefabricated and/or panelized
construction is
typically more expensive than stick-built construction and requires heavy
equipment
and specialized trades for installation. Panelized construction is seldom used
successfully to achieve high-performance structures due to the difficulty in
achieving
high-performance gasketing or sealing systems as well as the difficulty in
achieving
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good building envelope continuity at transitions between these systems and
other
portions of the construction such as the roof, the foundation, the window and
door
systems, etc. Prefabricated and/or panelized construction is rarely reusable.
[0005] Yet another method used is known as modular block construction.
Modular block construction uses smaller prefabricated modular units that
incorporate
a variety of interlocking modular shapes and sizes. Modular block systems on
the
market are typically systems where the blocks are forms for casting poured-in-
place
concrete. These systems require heavy equipment and specialized trades to
install
them. Others are not insulated or require finishes to be added and are not
weather
tight. None of these "block" systems are complete wall system assemblies. Most
of
these block systems are not reusable at all or, at least, not in their
original form.
Examples of some of these block systems are disclosed.
[0006] U.S. Patent No. 4,731,279 (1988, Isshiki) discloses an assembly block
formed from a poly-olefin foam. The block has a body that has a pair of
opposite
surfaces of which one is provided with a plurality of regularly spaced apart
holes,
while the other surface is provided with a plurality of regularly spaced apart
projections of which each can be fitted into one of the holes of another
block. At
least one bore extends through the body between the opposite surfaces for
receiving
a reinforcing bar. The blocks are lightweight and used for assembling a piece
of
furniture or a part of a building such as a table, stool, gate, or arch.
[0007] U.S. Patent No. 5,699,640 (1997, Bourgeois et al.) discloses stackable
and connectable foam building blocks. The building blocks include pairs of
parallel
side walls and multiple transverse members extending between the side walls at
regular intervals. Each end wall has a U-shaped cutout section at its top to
allow
concrete flow between cavities of adjacent blocks and for supporting rebars.
The
upper edge of the end wall defining the lower part of the U-shaped section
gradually
increases from the outer surface to the inner surface of the end wall to form
a
downward and inward sloping surface for the lower part of the U-shaped
section.
Each transverse member includes a pair of structures substantially identical
to the
end walls. The two structures are positioned back-to-back, such that each
cutout
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surface slopes inward and downward from the middle of the transverse member
towards the adjacent cavity and a ridge is formed where the two sloping
surfaces
meet. The inner surfaces of the side walls, transverse members and end walls
defining the cavities have a substantially vertical upper portion, and inward
and
downward sloping intermediate portion and outward and downward sloping bottom
portion. The inner surfaces of the side walls are curved where the side walls
meet
the transverse members and the end walls, giving the cavities a generally
octagonal
shape. Stacking members on the upper and lower edges of the side walls, and
connectors on outer surfaces of end walls connect blocks in horizontal rows.
[0008] U.S. Patent No. 6,164,035 (2000, Roberts) discloses a reinforced foam
block wall. The foam wall assembly includes vertical passageways that guide
wall
support elements. The wall assembly has a lower end and an upper support
element that are affixed to the wall support elements. The foam wall has inner
and
outer thermal barriers that thermally isolate the wall support elements.
[0009] U.S. Patent No. 5,992,102 (1999, Ozawa) discloses a cellular resin
block
and structural unit for an exterior structure using such block. The cellular
block is
integrally molded from suitable foamable resin and includes vertical grooves
at the
transversely opposite extremities, a vertical bar passage at the transversely
middle
and mortar wells extending on the upper end of the block. Brick is adhesively
laid on
the surface of the block using elastic mortar to form a structural unit.
[0010] U.S. Patent No. 6,557,316 (2003, Van Der Heijden) discloses a building
system having a plurality of building elements and connecting mechanisms where
each of the building elements has an upper and a lower surface which are
substantially parallel to each other and at least one opening extending from
the
upper surface to the lower surface, and each building element is adapted for
alignment with respect to an opening in another building element. Each
connecting
mechanism is dimensioned to fit within and extend through an opening in a
building
element and interconnect a plurality of building elements and deformation
members.
Deformation members are positioned between a lower surface of a building
element
and a connecting mechanism of another building element, and deformable by a
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predetermined force to induce a stress in the connecting mechanism of a
building
element such that it is pressed with a second predetermined force to another
building
element.
[0011] Each of the disclosed prior art devices has one or more of the
following
shortcomings on the way to creating a complete, sustainable building envelope.
These include, but are not limited to, a lack of gasketing between the blocks,
a lack
of a water shedding profile, a lack of a stand-alone integral structure, no
integral
raceways, no integral fastening system, and most are not reusable at all or,
at least,
not in their original form.
[0012] Therefore, what is needed is a reusable structural block that easily
forms a
complete building enclosure and can be used in place of stick-built
construction.
What is further needed is a reusable modular block wall system that includes
an
integral fastening system. What is also needed is a reusable modular block
system
that is lightweight, easy to handle and assemble with a minimal number of
tools and
specialized training.
SUMMARY OF THE INVENTION
[0013] Overview: The modular block system of the present invention is used to
create a structural building enclosure wall construction system that provides
a
reusable product, a high-performance thermal building envelope, flexibility in
the
installed shape and appearance, an easy interface with accessory building
materials,
a secure building system, and ease and speed of construction at a reasonable
cost.
The present invention is completely reusable in its original form,
incorporates the
means of accommodating usual electrical systems, has superior thermal
performance, and performs the structural needs necessary for low-rise
buildings or
infill curtain wall construction. The reusability characteristics allow for
installation,
demounting, and reinstallation of the components in their original form
without
modification.
[0014] Design Flexibility: The present invention provides a complete modular
wall system that can be assembled to meet most building designs without custom
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fitting of the parts and is compatible with other common building components
(windows, doors, etc.). The modular block system of the present invention
provides
components in sizes and configurations that allow maximum design flexibility.
The
component sizes of the structural block system of the present invention are
configured to meet common structural building component sizes such as, for
example, multiples of one foot (1') (30.38 cm). These suggested building sizes
are
only exemplary, and it should be understood that other sizes or multiples of
other
sizes may easily be made and are within the scope of the present invention. In
addition to providing a number of structural block configurations to allow
virtually
unlimited design arrangements, the present invention includes interior and
exterior
skins/facings that can serve as finishes or receive and support additional
surfacing
treatments and built-in assemblies. These facings (which, by way of examples,
can
be stamped or molded "veneers") can be changed to provide different aesthetic
"looks." The basic and optional facings also provide code-compliant fire and
weather
protection for the cellular foam or other insulating core material of the
blocks.
[0015] Structural System Parts: While one of the goals of the system of the
present invention is to have as few different parts as possible to simplify
and reduce
distribution and storage costs, an adequate number of parts and sizes are
necessary
to provide a complete and flexible building system. The structural block
system
includes one or more block configurations such as a horizontal block, a corner
block,
a sill cap block, a head cap block, a side jamb block, and the like. A line or
series of
specialized parts may be required for special conditions found in commercial
and
high-rise curtain wall system applications that are not typically used in
residential
construction.
[0016] Multiple uses: The structural block system of the present invention is
also useable in more or less formal situations. One scenario that the system
addresses is a do-it-yourself homeowner who wants to add a bedroom to his
existing
home. The present invention is configured so that the owner can demount the
existing blocks where the new room is to be added, buy the additional blocks
needed
at a local building supply house, take the lightweight blocks home on a
trailer or in a
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pickup truck, and lay up the new walls using a combination of the blocks that
were
removed and the newly purchased blocks. Another scenario would be use in a
disaster relief situation. The basic structural blocks of the present
invention could be
air dropped to a remote area and the victims could assemble their own
shelters.
These materials could be reused later in the permanent residences of the
victims. At
the other end of the spectrum, the structural block system of the present
invention is
usable as an infill wall system in high-rise commercial steel-framed
structures with
high-end finishes installed on either or both sides. By stacking and attaching
the
units to the structure at each floor level, the structural block system of the
present
invention would provide the same advantages as they provide in low-rise
structures.
[0017] Ease of Construction, storage, and handling: It is important that each
structural block be a stand-alone member that has all components of the system
in a
single part and can be assembled with a minimum of common hand tools. The
present invention provides structure, closure, insulation, and finishes in a
simple one-
step process. Each individual structural block of the present invention
provides the
interior and exterior finishes and weather protection. The present invention
has a
reliable installation procedure. In fact, the block structural configuration
makes the
installation process easy and intuitive, requiring minimal training and/or
installation
instructions. Components of the structural block system can be shipped in
small
vehicles and assembled and demounted without special tools or heavy equipment.
The individual structural blocks of the system of the present invention are
manageable (i.e. can be handled) by one person. The blocks can be stored
outside
and remain exposed without protection during the installation process.
[0018] Cost effectiveness: The modular block system of the present invention
has numerous advantages over other construction methods and systems. The
present invention is low tech and provides for efficient construction.
Construction is
faster than with conventional stick-built construction. The use of the
insulation as the
structure provides the cost-effective use of higher than current standard
insulation
values.
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[0019] Integral electrical raceways: In addition, the structural block system
of
the present invention provides optional integral raceways for normal in-wall
electrical
systems. The structure of the modular block is configured to provide both
horizontal
and vertical internal raceways for wiring in and between adjacent blocks,
avoiding
routing problems and surface-mounted electrical systems.
[0020] Structural Characteristics: The system of the present invention uses
the
molded insulating core as the entire structure of the component. It doesn't
have to
be filled with concrete or reinforcing steel or installed with internal
framing or other
structural elements. It does, however, include optional structure provisions
for
managing concentrated loads through the use of one or more tubular openings
that
extend from the top to the bottom of the blocks. The tubular openings are
sized to
accommodate standard sized construction lumber. The component blocks interlock
and are fastened together so that they maintain alignment and transfer
structural
loads. The system further allows for a staggered stacking pattern to provide
additional horizontal strength.
[0021] Integral Fastening System: The modular block system of the present
invention provides a means of structurally connecting the components to each
other.
This secure attachment also provides a continuous attachment from the
foundation
to provide resistance to high wind and earthquake loading. The fastening
system
also provides structural hold-down points for a roof system so that it can be
continuously attached to the foundation to resist wind uplift. The integral
fastening
system also reinforces the assembled blocks by means of post-tensioning the
blocks
together. The integral metallic fastening system, when fully installed, runs
continuously both vertically and horizontally in a structural spacing pattern
that
provides adequate security for the inhabitants of the structure. The integral
fastening
system of the structural blocks of the present invention provides the
connection
between the blocks and compresses the inter-block gaskets. In addition, the
fastening system provides adequate post-tensioning for short spans (one to two
blocks). The fastening system in each structural block configuration includes
at
least one connecting mechanism that extends through the insulating core with a
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fastener extending end and a fastener receiving end. The extending end of the
fastener is configured to connectively attach to the fastener receiving end of
an
adjacent block. The connecting mechanism may optionally include a securing
member that is embedded within the block core to prevent the connecting
mechanism from separating from the block, but also provides for free operation
of
the connecting mechanism. The modular block system includes an integral
fastening
system for speed and ease of construction and provides a molded structural
member
that does not violate the continuity of the insulation and structural
characteristics of
the component.
[0022] Complete High-performance Building Envelope: Unlike prior-art
systems, the modular block system of the present invention provides the entire
thermal envelope (insulation, vapor control, air barrier, structure, etc). The
basic
block is made of a molded closed-cell foam or other insulating material in a
thickness
that will provide a level of energy performance many times better than that of
normal
construction. An assembled wall system using the structural blocks of the
present
invention provides high-performance thermal insulation along with good sound
isolation in to out. The high-performance nature of the present invention (2
to 3
times more energy efficient than other systems) makes it a material of choice
for the
new "zero energy" market. Each structural component of the system includes a
gasket system that provides an airtight envelope to reduce air infiltration to
levels
much lower than conventional construction. The integral fastening system
described above assures a tight seal at all block interfaces. The present
invention
also provides a completely weather-tight assembly including a water-shedding
interlock profile complete with capillary breaks. The structural blocks of the
present
invention are weather resistant and don't require protection. The structural
configuration of the structural blocks of the present invention may also
optionally
provide for one or more capillary break structures to prevent water retention
at their
junctions when the structural blocks are assembled.
[0023] Sustainability: There is a current industry-wide need to meet
sustainability goals. There are several unique characteristics of the modular
block
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system of the present invention that are designed to meet these needs. The
modular block system of the present invention is totally reusable. Make a
mistake in
construction. It can be taken down and re-assembled correctly, no waste. Want
to
add a room? The floor plan can be changed using the original parts. While the
materials may not be 100% recycled content, the structural blocks of the
present
invention are one hundred percent (100%) reusable, unlike any other building
system
currently on the market. The minimal energy and resources required to
install/assemble the structural block system of the present invention is also
an
advantage in this market.
[0024] In summary, the present invention achieves these and other objectives
by
providing a reusable, energy-efficient modular block system. The reusable
modular
block system includes a lightweight, high-performance structural block having
an
insulating core, an inside facing and an outside facing, a gasketing system
connected to the structural block, and a fastening system within the
insulating core
that extends horizontally and vertically through the insulating block and
connects
both vertically and horizontally to the adjoining blocks. It is easy to store
and install.
Other aspects of the present invention include compliance with all applicable
building
codes and standards; in addition, it provides a means of securing the
components
together, to accessory building components, and to the foundation. It is easy
to store
and install.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIGURE 1 is a perspective view of one embodiment of the present
invention showing a horizontal structural block.
[0026] FIGURE 2 is a side transparent view of the embodiment in Fig. 1 showing
the inside facing, the shoulder, and the protruding edge of the central
portion.
[0027] FIGURE 3 is a side transparent view of the embodiment in Fig. 1 showing
the outside facing and the protruding edge of the central portion.
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[0028] FIGURE 4 is an end view of the embodiment in Fig. 1 showing the first
block end with the end shoulder and the protruding end edge of the central
portion.
[0029] FIGURE 5 is an end view of the embodiment of Fig. 1 showing the second
block end having the recessed channel.
[0030] FIGURE 6 is an end view of the embodiment in Fig. 1 showing the
internal
horizontal raceway created when two horizontal blocks are assembled.
[0031] FIGURE 7 is a top view of another embodiment of the present invention
showing one embodiment of a corner block.
[0032] FIGURE 8 is a top view of the embodiment in Fig. 7 showing the assembly
of the corner block with two of the horizontal blocks shown in Fig. 1 and the
vertical
internal raceways at each interlock of the assembly of two structural blocks.
[0033] FIGURE 9 is a top view of another embodiment of the present invention
showing another embodiment of the corner block.
[0034] FIGURE 10 is a top view of the embodiment in Fig. 9 showing the
assembly of the corner block with two of the horizontal blocks shown in Fig. 1
and
the vertical internal raceways at each interlock of the assembly of two
structural
blocks.
[0035] FIGURE 11 is a top view of one embodiment of the present invention
showing one embodiment of an end block.
[0036] FIGURE 12 is a side view of one embodiment of the present invention
showing a side jamb block.
[0037] FIGURE 13 is an end view of the side jamb block in Fig. 12 showing one
of
the recessed channels containing a piece of conventional lumber installed in
the
recess provided in the jamb block.
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[0038] FIGURE 14 is an end view of another embodiment of the present invention
showing a head cap block with optional conventional lumber.
[0039] FIGURE 15 is an end view of another embodiment of the present invention
showing a head cap block with an optional concentrated load support member and
optional conventional lumber installed in the recess provided in the head cap
block.
[0040] FIGURE 16 is an end view of another embodiment of the present invention
showing one embodiment of a sill cap block with optional conventional lumber
installed in the recess provided in the sill cap block.
[0041] FIGURE 17 is an end view of another embodiment of the flush sill cap
block in Fig. 16.
[0042] FIGURE 18 is an end view of another embodiment of the flush sill cap
block in Fig. 16.
[0043] FIGURE 19 is an end view of the embodiment in Fig. 1 showing its use as
a base block with a base sill fastener with optional conventional lumber
installed in
the interlock.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0044] The preferred embodiment(s) of the present invention is illustrated in
Figs.
1-19. Figure 1 shows a structural block 10 of the structural block system of
the
present invention. Structural block 10 includes an insulating core 20 with a
shoulder
23, an outside facing 40 (this may optionally wrap around the two ends), an
inside
facing 60, a gasketing system 80, a fastening system 100, and one or more
optional
tubular openings 120. Insulating core 20 is an insulating core material,
preferably a
closed-cell foam and, more preferably, a two-part closed-cell foam. Examples
of
acceptable closed-cell foams are polyurethane, polystyrene, foam glass, and
the like.
Outside facing 40 and inside facing 60 are preferably made of a code-compliant
fire
protection material such as, for example, a metal or other fire-retardant
cladding.
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Outside and inside facings 40, 60 are preferably about 0.030 inches (0.76 mm)
thick
and are connected to insulating core 20. Various conventional methods may be
used for attaching the facings 40, 60 to insulating core 20 such as
mechanical, mold-
injecting, adhesive, and other bonding techniques known to those skilled in
the
relevant art.
[0045] Figure 2 is a side, transparent view of structural block 10 showing the
inside facing 60. Shoulder 23 extends a predefined distance above the top of
inside
facing 60 and beyond the end of inside facing 60 at a first block end 16.
Shoulder 23
is instrumental in forming internal raceways, which will be more clearly
disclosed and
explained later. Insulating core 20 extends above a block top 12 and beyond
first
block end 16. As can be seen from the side view, a recess channel 24 extends
the
length of a block bottom 14 and a second block end 18. Recess channel 24 is
more
clearly illustrated in the remaining figures.
[0046] Gasketing system 80 includes an inside gasket 82 and an outside gasket
92. As illustrated, inside gasket 82 and outside gasket 92 are configured
along two
sides of structural block 10. Inside gasket 82 is connected along a pre-
selected
surface of block top 12 and first block end 16 while outside gasket 92 is
connected
along a pre-selected surface of block bottom 14 and second block end 18. When
two adjacent structural blocks 10 are connected to each other, gasketing
system 80
creates a weather tight seal spaced from the inside facing 60 and outside
facing 40
around the periphery of structural block 10. It should be understood that the
gasket
material may optionally surround the periphery of structural block 10 on all
sides, but
this only adds cost to the block without any noticeable improvement in system
performance. The gasket material is preferably a resilient material that
retains its
ability to provide a seal even when the structural blocks are disassembled and
reassembled.
[0047] Fastening system 100 typically includes at least one vertical
connecting
mechanism 102 and at least one horizontal connecting mechanism 110 for each
structural block 10; although in some limited block components of the present
invention, there may be only a vertical connecting mechanism, a horizontal
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mechanism, or no component of fastening system 100 whatsoever. The structural
block illustrated is one example of structural block 10 having a length of 4
feet (1.22
m) and a height of 1 foot (30.5 cm). As previously explained, structural block
10 may
be provided in various lengths and heights, but preferable in commonly used
multiples of sizes typical of the building trade. For example, structural
blocks 10
could be provided in 1 foot (30.5 cm) or'/2 foot (15.25 cm) increments in
either the
length or height dimensions, or both. It is further noted that the width of
structural
block 10 could vary as well depending on R-value or other structural reasons.
[0048] Figure 3 is a transparent side view of structural block 10 showing the
outside facing 40. Insulating core 20 extends along top 12 and first block end
16
while recess 24 extends along bottom 14 and second block end 18, which creates
a
male-female interlocking mechanism for assembling a plurality of modular
blocks 10
of the present invention. A plurality of vertical and horizontal connecting
mechanisms 102, 110 are within insulating core 20.
[0049] Turning now to Figure 4, there is illustrated an end view of first
block end
16. Insulating core 20 has a central portion 22, an outside portion 26, and an
inside
portion 30. Central portion 22 has a shoulder 23 that extends a predefined
distance
above the top of inside portion 30 and extends beyond first block end 16 such
that it
is extending toward the viewer of Fig. 4. Recess channel 24 along bottom 14 is
illustrated. Inside gasket 82 is connected to the inside portion 30 of
insulating core
20 and spaced from inside facing 60. Outside portion 26 includes optional
capillary
break structures 27. Outside facing 40 has an optional fiashing extension 28
that
extends over the top of outside portion 26 and up a predefined distance along
the
extension of central portion 22. As can be seen, outside gasket 92 does not
extend
over the entire length of first block end 16 of insulating core 20. It should
be noted
that the preferred embodiment illustrates the inside facing 60 and the outside
facing
40 as optionally wrapping around the top 12 and the bottom 14. It also shows
that
this wrapping of the facings is not necessary.
[0050] Figure 5 shows an end view of second block end 18. Outside gasket 92
extends along the bottom of central portion 22 and up the end of central
portion 22 at
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second block end 18 and spaced from outside portion 26. Recess channel 24
extends the entire length of central portion 22 at this second block end 18.
Recess
channel 24 and the extension of central portion 22 provide the interlocking
mechanism in both the horizontal and vertical direction that makes assembly of
the
modular block system of the present invention easy and intuitive.
[0051] Figure 6 is a cross-sectional view of two structural blocks 10, 10'
assembled to each other as viewed from first block end 16. It should be noted
that
the method of assembly does not require the vertical junctions of blocks 10,
10' to be
staggered because of fastening system 100 and the interlocking features of
blocks
10. The extension of central portion 22' and shoulder 23' of the lower block
10' mate
with recess channel 24 of the upper block 10. Vertical connecting mechanism
102
extends through the central portion 22 of insulating core 20 from top 12 to
bottom 14.
[0052] In the embodiment illustrated, vertical connecting mechanism 102 has an
elongated member 104 with a fastener extending end 105 and a fastener
receiving
end 106. Fastener ends 105, 106 are matingly configured so that the fastener
extending end 105 connectively attaches to the fastener receiving end 106' of
a
vertical connecting mechanism 102' in an adjacent block 10'. In this example,
fastener extending end 105 has a predefined number of threads and fastener
receiving end 106 has an outer structure shaped like a nut with a threaded
internal
recess. As the blocks 10, 10' and the connecting mechanisms 102, 102' are
aligned,
the fastener extending end 105 of the top block 10 is threaded into the
fastener
receiving end 106' of the bottom block 10' by turning fastener receiving end
106. As
tensioning occurs, inside gasket 82 and outside gasket 86 are compressed
between
blocks 10, 10' creating a weather-tight seal. It should be understood that
Fig. 6
illustrates the assembled blocks before tensioning in order to show the
positions of
the inside and outside gaskets 82, 86, respectively. Fig. 6 also illustrates
an optional
retaining member 107 connected to connecting mechanism 102. Retaining member
107 is retained by central portion 22 of foam block 20 to prevent accidental
loss of
connecting mechanism 102.
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[0053] One of the key features of the modular block system of the present
invention is the continuous, horizontal, internal raceway 200 created by the
assembly
of adjacent structural blocks 10. For each run of horizontal blocks 10, a
horizontal
raceway is formed by the central portion 22 and the inside portion 30. The
surfaces
that create raceway 200 may optionally be covered with an electrically
conductive
material for grounding purposes. As will be explained later, continuous,
vertical,
internal raceways are similarly created upon assembly.
[0054] Turning now to Figure 7, there is illustrated a top view of one
embodiment
of a corner block of the present invention. Like the horizontal block
previously
discussed, corner block 10a has central portion 22 with shoulder 23, outside
portion
26, inside portion 30, outside facing 40, inside facing 60, first block end
16, second
block end 18, vertical connecting mechanism 102, horizontal connecting
mechanism
110, and tubular openings 120. Recess 24 at second block end 18 is
substantially
perpendicular to the central portion 22. Outside portion 26 and outside facing
40
wrap around second block end 18 forming an outside wall corner. As shown,
tubular
opening 120 at second block end 18 provides access to fastener receiving end
106
for tensioning horizontal connecting mechanism 110.
[0055] Figure 8 illustrates the use of the embodiment of corner block 10a with
horizontal blocks 10. Line 300 indicates the center line for outside gasket 92
and line
310 indicates the center line for horizontal connecting mechanism 110. First
block
end 16 connects with second block end 18 forming an internal, vertical raceway
210
at each junction between adjacent blocks.
[0056] Turning now to Figure 9, there is illustrated a top view of another
embodiment of a corner block of the present invention. In this embodiment,
corner
block 10b has central portion 22 with shoulder 23, outside portion 26, inside
portion
30, outside facing 40, inside facing 60, first block end 16, second block end
18,
vertical connecting mechanism 102, horizontal connecting mechanism 110, and
tubular openings 120. The extension of central portion 22 at first block end
16 is
substantially perpendicular to the recess channel 24 at second block end 18.
Outside portion 26 and outside facing 40 wrap around first block end 16
forming an
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outside wall corner. As shown, tubular opening 120 at first block end 16
provides
access to fastener receiving end 106 for tensioning horizontal connecting
mechanism 110.
[0057] Figure 10 illustrates the use of the embodiment of corner block 10b
with
horizontal blocks 10. Line 300 indicates the center line for outside gasket 92
and line
310 indicates the center line for horizontal connecting mechanism 110. First
block
end 16 connects with second block end 18 forming an internal, vertical raceway
210
at each junction between adjacent blocks.
[0058] Figure 11 illustrates a top view of one embodiment of an end block 10c.
End block 10c includes insulating core 20 having a central portion 22 with
tubular
opening 120, and vertical and horizontal connecting mechanisms 102, 110,
respectively. The facing may be either outside facing 40, inside facing 60, or
both
depending on the use of the end block. It should be also understood that any
of the
structural blocks of the present invention may have the same facing material
on both
sides of the structural blocks, i.e., inside facing or outside facing,
depending on
where the wall is being located. A narrower end block is also contemplated
that
would not have a central portion 22.
[0059] Figures 12 and 13 illustrate one embodiment of a side jamb block 10d.
Fig. 12 shows a side view of one embodiment of a side jamb block 10d with
central
portion 22, outside portion 26, inside portion 30, outside facing 40, and
inside facing
60. Fig. 13 is a top end view of side jamb block 10d showing insulating core
20 with
recess channel 24 and 24' on either side of central portion 22 between inside
portion
26 and outside portion 30. In one of the recess channels 24, 24', a piece of
convention lumber 2 may be connected to provide a surface for attachment of an
accessory door or window unit. Side jamb block 10d may optionally be provided
as
left or right side jambs for doors or with the same or different inside
facings for indoor
use.
[0060] Figure 14 illustrates an end view of one embodiment of a head cap block
10e. Like previous structural blocks, head cap block 10e has an insulating
core 20
with central portion 22, outside portion 26 and inside portion 30. Outside
facing 40 is
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CA 02635449 2008-06-19
attached to outside portion 26 and inside facing 60 is attached to inside
portion 30.
Shoulder 23 of central portion 22 is adjacent inside portion 30 and insulating
core 20
has gasketing system 80 connected thereto. In this embodiment, outside gasket
92
seals head cap block 10e to the wood. In this way, the wood is sealed to the
window/door as in conventional construction for air barrier continuity. Recess
channel 24 may optionally contain conventional lumber 2 held in place by a cap
fastener 114, which may be the same or similar to a sill cap fastener 115
disclosed
below.
[0061] Figure 15 illustrates the embodiment in Fig. 14 but with an additional,
optional member. Within recess channel 24, there is illustrated a concentrated
load
support member 116. Load support member 116 is a reinforcing structural lintel
section (preferably two angled components as shown) that provides additional
load-
bearing support to the structural blocks. Load support member 116 preferably
attaches to the vertical connecting mechanism in a similar way that one
connecting
mechanism attaches to another connecting mechanism.
[0062] Figures 16-18 illustrate various embodiments of a sill cap block 10f.
Fig.
16 is an end view of sill cap block 10f showing an insulating core 20 with an
outside
facing 40 and an inside facing 60. Because it is used as a sill cap, sill cap
block 10f
has only an outside gasket 92. In shape, the embodiment of sill cap block 10f
is
similar in profile to side jamb block 10d. Sill cap block 10f has a central
portion 22,
an outside portion 26, an inside portion 30, and recess channels 24, 24' on
either
side of central portion 22 between outside portion 26 and inside portion 30.
In this
configuration, a piece of convention lumber 2 in inserted within recess
channel 24' in
order to provide a flat surface for receiving the bottom of a window. Fig. 17
illustrates another embodiment of a sill cap 10f'. In this embodiment, sill
cap 10f' has
only one recess channel 24 and a top 12 that is substantially flat over its
entire top
surface without any part of central portion 22 extending beyond top 12 (these
flat
versions are for windows that are set farther inward in the block section
where the
top of the block shows outside beyond the window sill). Fig. 18 illustrates
another
embodiment of a sill cap. In this embodiment, sill cap 10f' has one recess
channel
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CA 02635449 2008-06-19
24 and a top 12 that is substantially flat over a major portion of its top
surface. A
recessed shoulder 25 is created along the top outside portion 26 of insulating
core
20. Outside facing 40 preferably has an optional flashing extension 28 that
covers
recessed shoulder 25. Flashing extension 28 provides flashing for water
running off
of the sill, which is set back (inward) on block 10.
[0063] Figure 19 illustrates the interface between a structural block 10 of
the
present invention and a base such as a foundation 5. All conventional
foundations
have a sill board 7 installed on the top surface of the foundation 5. The sill
board 7 is
typically pressure-treated lumber that is secured in place with securing
straps or
anchor bolts (not shown) that are anchored in the concrete of the foundation.
A
structural block 10 that is used as the starter blocks on a base/foundation
requires a
means for securing the block 10 to the foundation. Alternately, a similar wood
sill
board would be attached to a wood floor deck or platform. A base sill fastener
115 is
configured for attachment to the connecting mechanism 102 of a block 10 at
fastener
extending end 105. Base sill fastener 115 has a threaded recess on one end for
receiving fastener extending end 105 and a mechanism for attaching to the sill
board. In the illustration in Fig. 19, the mechanism for attaching to the sill
board 7 is
a screw configuration that screws into the sill board 7 to anchor structural
block 10 to
the base/foundation 5.
[0064] Although the preferred embodiments of the present invention have been
described herein, the above description is merely illustrative. Further
modification of
the invention herein disclosed will occur to those skilled in the respective
arts and all
such modifications are deemed to be within the scope of the invention as
defined by
the appended claims.
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