Masonry Structure and Apparatus and Process for Spacing Block in the Structure

1. Field of the Invention

This invention relates to a masonry structure and an apparatus and process for spacing blocks in the structure and is more particularly concerned with a spacer element which in combination with conventional masonry blocks and mortar form a masonry wall.

2. Description of the Prior Art

In the past numerous devices have been suggested for aiding a person in building a wall and also in facilitating the spacing of the bricks or masonry blocks from each other. A search of the prior art revealed the following U.S. Pat. Nos.:

2,543,716--Carini

2,679,745--Bartram

3,030,738--Brewer et al.

3,411,257--Yaremchuk

3,641,731--Winfree

3,902,296--Thomas

Of the above listed patents, the patent to Winfree U.S. Pat. No. 3,641,731 appears to be most significant in that in FIGS. 6-9 it reveals a stamped metal spacer employed for spacing the bricks apart sufficiently for mortar to be poured downwardly into the crevices between adjacent bricks. The Winfree procedure, however, requires retaining structures on opposite sides of bricks so as to arrest the outward flow of the mortar which is poured down through the space between bricks.

Briefly described, the present invention includes a spacer element which is employed for spacing one masonry block or brick from the next adjacent masonry block or brick. Such a spacer element is embedded in the soft mortar and has a frame from which spacer fingers project for engaging the opposed surfaces of adjacent bricks or masonry blocks in order to dictate the space between such surfaces. The spacer element is formed of plastic which is injection molded.

In one form of the invention, the spacer element includes rectangular frame formed of pairs of respectively parallel rods or struts, the ends of which are joined. Protruding from the corners of the frame in opposite directions are opposed pairs of spacer fingers or protrusions which are aligned with each other along an axis perpendicular to the frame. The frame has smaller dimensions than a conventional brick so as to be disposed between adjacent bricks and be wholly embedded in the mortar.

In another embodiment, a smaller U-shaped spacer frame or body formed of three struts, two struts of which are parallel to each other and are joined at their ends by the third strut. The spacer fingers or elements project along axes which are parallel to each other and perpendicular to the struts. Certain protrusions are at the corners of the U-shaped frame and others are spaced inwardly from the ends of the parallel struts.

In a third embodiment, the spacer element includes a right angularly disposed open body formed of parallel, horizontally disposed struts joined to parallel vertically disposed struts, the ends of the struts being joined by laterally extending parallel connector struts. A plurality of spacer fingers are carried by each of the struts and the fingers of each pair of fingers extend in opposite directions from each other along axes which are parallel to each other and perpendicular to the axes of the struts from which they extend.

Accordingly, it is an object of the present invention to provide an apparatus for producing a masonry structure, which apparatus will positively space one surface of a masonry block from the adjacent surface of another block, the apparatus being inexpensive to manufacture, durable in structure and efficient in operation.

Another object of the present invention is to provide a process of producing a masonry structure, which process can be carried out by a novice and produce a masonry structure in which the bricks or masonry blocks thereof are uniformly spaced from each other.

Another object of the present invention is to provide an apparatus for producing a masonry structure which apparatus is readily and easily inserted into soft mortar so as to space adjacent bricks from each other by a prescribed distance.

Another object of the present invention is to provide an apparatus for producing a masonry structure, which apparatus can be readily and easily produced by injection molding.

Other objects, features and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings wherein like characters of reference designate corresponding parts throughout the several views.

FIG. 1 is a fragmentary, partially broken away vertical, sectional view of a portion of a masonry structure using the spacer elements constructed in accordance with the present invention;

FIG. 2 is a prospective view of two different embodiments of the spacer element of the present invention and a brick shown in broken lines, the spacer elements being positioned appropriately adjacent to that brick; and

FIG. 3 is a view similar to FIG. 2 but still showing a third modified form of the present invention.

Referring now in detail to the embodiments chosen for the purpose of illustrating the present invention, numeral 10 in FIG. 1 denotes generally a masonry wall structure formed of a plurality of conventional masonry blocks or bricks 11a, 11b, 11c and 11d. The bricks 11a and 11b form a first row of a course of bricks which are mounted on a flat, horizontally disposed upper surface 13 of an appropriate foundation 12. As is customary, the foundation 13 is of a width approximately equal to or greater than the width of one of the bricks 11a, 11b, 11c or 11d.

It will be understood by those skilled in the art that a row of bricks, such as bricks 11a and 11b, form a first row over the foundation 12 and a row of bricks, such as bricks 13c and 13d form a second row over the first row, etc. Each of the bricks, as is conventional, is spaced apart from the next adjacent brick by a prescribed amount. Mortar or concrete in a wet plastic or pliable form is employed between the surfaces of the adjacent bricks together and solidifies to bind the bricks together.

According to the present invention, spacer elements are employed for dictating the spacing of the bricks apart, one form of the spacer element being denoted generally by the numeral 20, another form of the spacer element being denoted generally by the numeral 30 and still a third form of the spacer element being denoted generally by the numeral 40.

As best seen in FIG. 2, the spacer element or apparatus 20 includes a flat, open, rectangular frame or base which is formed of a pair of longitudinally extending spaced, parallel, side struts 21, the ends of which are joined by spaced, parallel, straight, transversely extending opposed end rods 22, also of equal length. Each of the struts 21 and 22 is cylindrical in shape, being formed of plastic which is sufficiently rigid to maintain its shape and yet will flex, when necessary.

At the four corners of the frame formed by the struts or rods 21 and 22 are pairs of oppositely protruding, spacer fingers, protrusions or prongs 23a and 23b. Each finger 23a or 23b is a conical member, the proximal end of which is mounted integrally on the periphery of the struts 21 and 22. Each pair of adjacent fingers 23a and 23b is provided with a common axis which is perpendicular to the axis of the struts 21 and 22 and intersect with these strut axes at the corners of the frame. Preferably, each finger 23a or 23b is of approximately the same length and terminates in a rounded point or tip at its distal end. The distance between the points or tips of adjacent pairs of prongs 23a, 23b determines the spacing between one brick and the next adjacent brick or the surface 13 of the foundation 12, as the case may be. Usually this spacing is from about 1/4 inch to 1/2 inch and preferably about 3/8 inch for conventional bricks; however, it may be varied, as desired.

All of the tips of the prongs or fingers 23a, terminate in a common plane parallel to the plane of the frame formed by the struts 21 and 22. Also, the tips of the prongs or fingers 23b terminate in a common plane which is parallel to the plane of the tips 23a and also parallel to the plane of the frame formed by the rods 21 and 22.

Preferably, if the spacer element 20 is to be employed with a conventional brick, the length of the frame, i.e., of struts 21 is approximately 6 inches and the width of the frame, i.e., the length of the struts 22 is approximately 23/4inches. A conventional brick is both longer and wider and, therefore, when the spacer element 20 is employed, it will be spaced inwardly of the facing surfaces of the brick, as seen in FIG. 2. The struts 21 and 22 are preferably cylindrical rods about 1/8 inch in diameter.

When the spacer element 20 is to be employed, it is, for example, embedded in the soft motar 14 along the upper surface 13 of the foundation 12 so that one spacer element 20 receives one brick such as brick 11a or 11b, as the case may be. The spacer element 20 is inserted into the soft mortar 14 so as to be wholly embedded therein, being inwardly of the facing surfaces of the bricks, such as bricks 11a and 11b.

In like fashion, additional spacer elements 20 are mounted on top of the bricks which form the first row so as to provide spacer elements 20 for the second row, etc. Usually it is preferable to utilize a single spacer element 20 on a single brick, such as brick 11e in FIG. 2, the side struts 21 being spaced inwardly from the side faces of the brick 11e and the end struts 22 being spaced inwardly from the ends of the brick 22 so as to be centered on the brick.

Since the spacer fingers 23a and 23b will space the bricks of each row apart by the appropriate 3/8's inch or such other spacing as is desired, there is no need to delay installing subsequent rows of brick, one upon the other, since there is little or no danger of settling as when the weight of the brick causes the mortar to exude from between adjacent bricks.

As the bricks of a particular row are arranged end to end with appropriate mortar 14 disposed therebetween, the end spacer elements 30 are embedded in this end mortar. Each end spacer element 30 is formed of a U-shaped frame having straight, spaced, parallel side struts 31 one end of each of which is joined to the other end thereof by an end of the other strut 32. At the corners formed by a side strut 31 and an end strut 32 are the opposed pairs of oppositely protruding spacer prongs, fingers or protrusions 33a and 33b arranged in pairs along a common axis which is perpendicular to and intersects the axes of the struts 31 and 32 which form that corner. Additional fingers, such as fingers 33c and 33d are provided on the struts 31 intermediate the ends thereof. These spacer prongs or fingers 33c and 33d are arranged in pairs along axes which are perpendicular to the axis of the strut 31 and parallel to the axes of the prongs or fingers 33a and 33b, as illustrated in FIG. 2.

In use, the mortar 14 is inserted into a position between adjacent bricks, such as adjacent bricks 11a and 11b, and then the element 30 is inserted in a downward direction into the mortar. Additional motar may be filled in so as to enclose the spacer element 30. The bottom or outer ends 34 of the struts 31 rest upon the surface created by either the foundation or the row of bricks, the distance between the ends 34 and the pairs of prongs 33c and 33d being greater than 3/8's inch or greater than the distance between adjacent prongs 23a and 23b so that the prongs 33c and 33d are positioned for engagement by the ends of the bricks, such as bricks 11a and 11b.

It will be understood that in the event that a short brick, such as a half brick 11d is employed in the wall, this spacer element 30 may be employed in a horizontal position between the upper and lower faces of the bricks, such as the upper face of brick 11b and the lower face of brick 11d as seen in FIG. 1.

The open space between the ends 34 and between the struts 31 will facilitate the easy insertion of the spacer element 30 in place and also facilitate the appropriate positioning of the element 30 when the ends 34 come to rest on a flat surface, such as the surface 13 depicted in FIG. 1. Like the spacer element 20 the element 30 remains in place as the mortar hardens and will prevent the mortar from being extruded from between adjacent ends of the bricks. Since the spacer elements 20 and 30 are made of plastic, they are flexible and, even though they may have warped during the cooling of the plastic in the element, the plastic is sufficiently flexible that the weight or pressure of one brick will be sufficient to cause the struts 21, 22 or 31, 32, as the case may be, to become aligned and insure that each of the fingers is, therefore, disposed in engagement with its appropriate surface of a brick.

The third embodiment of the present invention, includes an apparatus or spacer element 40 which functions both as a spacer for the horizontal surface of a brick and as a spacer for the vertical end thereof. In more detail, this spacer element 40 includes a horizontal base or frame formed of a pair of longitudinally extending spaced, parallel, straight rods or struts 41, the ends of which are joined by a straight, transverse connector rod or strut 42. At the corners formed by the rods 41 and 42 are pairs of opposed vertical prongs or fingers 43a and 43b which are identical to the prongs 23a and 23b. In like fashion, the rods 41, intermediate their ends, are provided with opposed pairs of prongs 43c and 43d which are the same lengths as the prongs 43a and 43b. Thus, these four prongs space the bricks, such as brick 11c vertically, the tips of the prongs 43a and 43c engaging the bottom surface of brick 11c and the lower ends of the prongs or fingers 43b and 43d engaging the upper surfaces, such as bricks 11a and 11b as shown in FIG. 1.

It will be understood that the ends of the rods 41 protrude beyond the end of the brick 11c which it cradles and is provided with a pair of upstanding rods or struts of a vertical frame 44. The upper ends of the rods are connected by a horizontally disposed connector end rod or struts 45. The rods 44 are substantially identical in length to the rods 31 and the rod 45 is identical to rod 32. At the corners formed by the rods 44 and 45 are the opposed prongs or fingers 43e and 43f with axes perpendicular to the axes of rods 44 and 45.

The advantage of the structure depicted in FIG. 3, namely, the spacer element 40 includes the fact that the first frame formed by the rods 41 and 42 is longer than the second frame and is open at its end and, therefore, can be inserted quite readily into the mortar by being moved angularly into the mortar which has been laid along both the horizontal surface and the vertical surface. Thus, brick 11c is spaced both from the bricks 11a and 11b as well as from the brick 11d, the first frame being shorter than the length of the brick and the second frame shorter than the first frame and shorter than the height of the back.

Usually the bricks are laid successively in rows with the pliable mortar being applied to a surface or surfaces of either the brick to be laid or the surface against which the brick will be placed. The appropriate spacer elements 20, 30 or 40 are then inserted into the pliable mortar prior to installation of the brick it spaces.

It will be obvious to those skilled in the art that many variations may be made in the embodiment here chosen for the purpose of illustrating the present invention without departing from the scope thereof as defined by the appended claims.