Method and apparatus to achieve consistent spacing between layers of modular construction

[00002] The present application is a continuation and claims priority of U.S. Pat. No. 6,553,737 which issued on Apr. 29, 2003.

[00003] The present invention relates generally to brick and block wall construction and, more particularly, to a method and apparatus to achieve a consistent spacing between layers of bricks and/or blocks.

[00004] A number of construction techniques and devices/tools have been developed to assist masons and bricklayers in achieving a consistent and uniform spacing between layers of bricks and/or blocks of a constructed wall. Typically, the spacing between brick/block layers is occupied by mortar or some other adhesive material. A consistent and uniform mortar thickness not only adds to the aesthetic characteristics of a constructed wall but also provides structural stability that helps prevent premature strain on the structure that may lead to structure collapse.

[00005] These known spacers are limited however in application with bricks/blocks of different sizes. Known spacers primarily function to achieve an equal spacing between adjacent bricks/blocks of the same layer. Other spacers work to achieve a consistent thickness between layers, however, these spacers are particularly suited to cement blocks and are somewhat limited in application with bricks. These spacers typically include teeth that fill into interior cavities of the blocks, and as such, the spacers must be manufactured to fit a particular size block with specific cavity measurements. As a result, different spacers are needed for different size blocks and/or bricks.

[00006] It would therefore be desirable to design a construction tool that provides consistent spacing between brick layers of a constructed wall wherein the tool is applicable with bricks and blocks of multiple lengths and widths.

[00007] The present invention is directed to a method and apparatus to achieve a consistent spacing between layers of bricks/blocks. A spacer is provided that includes at least one rail of plastic, steel, rebar, or the like that runs along a top surface of a brick/block. At least one transverse rail is connected to the length-running rail. The transverse rail is also constructed of plastic, steel, rebar, or the like and runs width-wise along the top surface of the brick/block. Connected to the rails is a number of spacing studs that define a desired mortar depth. The spacing studs may include removable clips that are configured to engage the rails. Accordingly, the clips have a height tantamount to the desired mortar depth. The present invention may alternatively include a kit comprising the rails, clips, and bricks/blocks.

[00008] In accordance with one aspect of the present invention, a spacer having first and second parallel rails extending along a length of a modular construction material is provided. The spacer also includes at least one connecting rod connecting the first and second parallel rails to another. A plurality of spring studs is also provided. The spacing studs are connected to the rails to define a desired mortar depth between modular construction material layers.

[00009] In accordance with another aspect of the present invention, a spacing apparatus is provided. The spacing apparatus is configured to achieve a relatively consistent mortar depth between modular construction material layers. The spacing apparatus includes at least one lengthwise rail extending along a length of at least one modular construction material and at least one transverse rail extending along a width of a modular construction material. The spacing apparatus also includes a number of clips wherein each clip has a height indicative of the desired mortar depth. Each clip is configured to removably engage a lengthwise rail or a transverse rail.

[00010] In accordance with a further aspect of the present invention, a spacing clip removably engagable with a pair of parallel rails extending along a length of a modular construction material is provided. The spacing clip includes a first end and a second end. Each end has a height equal to a desired mortar depth as well as a groove to receive a rail extending along the length of the modular construction material. The clip also includes a cross bar connecting the first end and the second end.

[00011] Various other features, objects and advantages of the present invention will be made apparent from the following detailed description and the drawings.

[00022] The present invention will be described with respect to a spacing apparatus that may be used during construction of a wall out of modular construction materials. Herein, the terms “brick” and “block” may be interchanged and used to describe any modular construction material used for wall construction.

[00023] FIG. 1 is a pictorial view of a brick wall during construction incorporating one embodiment of the present invention. The wall 10 includes a number of bricks 12 that are arranged in layers in accordance with known construction techniques. Each brick 12 is securely positioned with a layer of adhesive material 14 such as mortar. To achieve a uniform and consistent spacing between each layer of bricks, a spacer 16 is implemented. The spacer 16 is designed to be positioned along a top surface 12a of the bricks.

[00024] Referring to FIG. 2, in one embodiment, spacer 16 includes a pair of parallel rails 18. The rails 18 extend length-wise along a top surface of the bricks. Connecting rails 18 are a pair of transverse connecting rods 20. The connecting rods provide stability to the spacer and extend across the width of the brick. Affixed to the rails 18 and rods 20 are a number of spacing studs 22. Studs 22 have a height defining a desired adhesive or mortar depth. Each stud includes a first end 22a and a second end 22b. End 22a extends upwardly from the rail or rod whereas end 22b extends downwardly. End 22a is designed to abut the under surface of a laid brick whereas end 22b is designed to abut the top surface of a laid brick. Alternatively, spacer 16 may include a single rail 18 extending along a center length of the brick with at least one rod 20 extending along a width of the brick. Preferably, spacer 16 is formed of galvanized steel but may be fabricated from other materials such as plastic, polymer composites, or the like.

[00025] Referring now to FIG. 3, a top view of a portion of that shown in FIG. 1 is illustrated. As illustrated, rails 18 are ideally positioned on the top surface 12a of a secured brick such that the distance between a first rail 18a and the edge 24 of the brick 12 is the same as the distance between second rail 18b and an opposite edge 26 of brick 12. As further illustrated, rails 18a, 18b extend length-wise along the top surface of each brick of the layer. However, a modular spacer is also contemplated wherein multiple spacers are linearly connected to form a spacer that extends along the length of the entire brick layer.

[00026] Referring now to FIG. 4, a cross-sectional view of FIG. 3 taken along line 4—4, the consistent mortar depth achieved with brick spacer 16 is illustrated. As illustrated, studs 22 define a desired mortar depth between layers of bricks 12. As also illustrated, spacer 16 is permanently secured with mortar 14 between the layers of bricks 12. As such, spacer 16 helps maintain the stability of the finished wall or structure.

[00027] Heretofore described is a spacer 16 wherein the rails 18 and the connecting rod 20 are molded or cast in a single unitized assembly. Additionally, rod 20 may be welded to rails 18a, 18b. However, in another embodiment, connecting rod 20 may be incorporated as an independent spacing clip, as will be described with respect to FIGS. 5-7.

[00028] Referring now to FIG. 5, connecting rod 20a is illustrated in engagement with rails 18a, 18b. Rod 20a, in this embodiment, includes a curvilinear or sinusoidally-shaped connecting section 28a connecting a first end 30a and a second end 32a to one another. Each end 30a, 32a as well as portions 34a, 36a of the connecting section 28a have a height equal to a desired mortar depth. At each end 30a, 32a is a groove 38a, 40a configured to receive rails 18a, 18b, respectively. Each U-shaped groove 38a, 40a has a diameter or width sufficient to securely engage the diameter of rails 18a, 18b. Connecting rod 20a is designed to securely receive rails 18a, 18b. To further secure the rails 18a, 18b within grooves 38a, 40a welding material 42 may be implemented.

[00029] Referring now to FIG. 6, an alternate connecting rod 20b is illustrated. Connecting rod 20b includes a first end 30b and a second end 32b connected by a connecting section 28b. Each end 30b, 32b and intermediate portion 34b have a height equal to a desired mortar depth. Grooves 38b, 40b are configured to receive rails 18a, 18b. One intermediate portion 34b is shown, but clip 20b may include more than one intermediate portion. Preferably, each intermediate position is equidistantly positioned along connecting section 28b. Each groove 38b, 40b is designed to engage a corresponding groove (not shown) of rail 18a, 18b. Alternately, each end 38b, 40b is fabricated from a resilient material that may be flexed such that the grooves 38b, 40b can be temporarily widened to engage rails 18a, 18b.

[00030] Referring now to FIG. 7, another embodiment of a clip is shown. Clip 44 is designed to engage a rail 18 independent of a transverse rod 20. That is, clip 44 may be positioned anywhere along the length of rail 18 and is not necessarily connected to connecting rod 20. Clip 44 has a circular cross-section with a diameter equal to the desired mortar depth. Groove 46 is configured to receive rail 18 and has a width equal to the diameter of rail 18. The number of clips 44 utilized along each rail is a matter of design choice, but a sufficient number to adequately support the length of the rail should be used.

[00031] FIG. 8 is a pictorial view of a cement block wall incorporating a spacing apparatus particularly useful for cement blocks. Spacer 48 includes a pair of rails 50 extending along a top surface 52 of blocks 54. Diagonally connecting rails 50 is a connecting rod 56. To achieve a desired mortar depth, a number of spacing studs 58 or clips similar to those heretofore described are attached to the rails 50 and rod 56.

[00032] To achieve a consistent and uniform spacing between layers of bricks and/or blocks, a mason or bricklayer positions a spacer along a top surface of the brick or blocks. Mortar is then placed over the spacer and bricks/blocks. Preferably, an excessive amount of mortar is used such that the placement of the next layer of bricks or blocks causes the mortar to compact and fill any gaps or space between the layers. The excessive mortar that is excreted from between the bricks/blocks and is then removed so that mortar is not wasted and the finished wall is aesthetically pleasing. The spacers heretofore described permanently remain between the layers of bricks/blocks and become part of the finished product or construction.

[00033] In accordance with one embodiment of the present invention, a spacer having first and second parallel rails extending along a length of a modular construction material is provided. The spacer also includes at least one connecting rod connecting the first and second parallel rails to another. A plurality of spring studs is also provided. The spacing studs are connected to the rails to define a desired mortar depth between construction layers.

[00034] In accordance with another embodiment of the present invention, a spacing apparatus is provided. The spacing apparatus is configured to achieve a relatively consistent mortar depth between layers of modular construction material. The spacing apparatus includes at least one rail extending along a length of at least one modular construction material and at least one transverse rail extending along a width of a modular construction material. The spacing apparatus also includes a number of clips wherein each clip has a height indicative of the desired mortar depth. Each clip is configured to removably engage a rail or a transverse rail.

[00035] In accordance with a further embodiment of the present invention, a spacing clip removably engagable with a pair of parallel rails extending along a length of a modular construction material is provided. The spacing clip includes a first end and a second end. Each end has a height equal to a desired mortar depth as well as a groove to receive a rail extending along the length of the modular construction material. The clip also includes a cross bar connecting the first end and the second end.

[00036] The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.