Modular construction blocks, building structures, kits, and methods for forming building structures

[0001] This invention relates generally to bricks and building structures, and more particularly to modular construction blocks, building structures, kits, and methods for forming building structures.

[0002] Conventionally, bricks and blocks for constructing building structures include solid bricks made of clay and blocks made of concrete or cement having two chambers in the interior of the blocks.

[0003] U.S. Pat. No. 6,161,357 issued to Altemus discloses forming a wall with bricks formed of clay or similar materials and having two or three cylindrical passageways running from top to bottom, and a cylindrical passageway running from one end to the opposite end. The passageways are disposed in two different planes and intersect. Also, the bricks are interlocking and may be filled with concrete and reinforced with rods or posts.

[0004] U.S. Pat. No. 5,457,926 issued to Jensen discloses a lightweight, non-cementitious, resilient, interlocking, plastic foam block which can be assembled with other like blocks to produce a light impervious wall. The foam block includes two vertically-extending passageways. The blocks can each be secured to abutting blocks with adhesive. Concrete and re-bar can extend through hollows in the blocks in conventional fashion.

[0005] There is a need for still further modular construction blocks, building structures, kits, and method for forming building structures.

[0006] The present invention provides, in a first aspect, a modular construction block which includes a preform having a top surface, a bottom surface, opposite side surfaces, and opposite end surfaces. The preform includes a first horizontal passageway extending between the opposite end surfaces, a pair of spaced-apart vertical passageways extending from the top surface and intersecting the first horizontal passageway, and a pair of spaced-apart second horizontal passageways extending between the opposite side surfaces and intersecting the first horizontal passageway and the pair of vertical passageways.

[0007] The present invention provides, in a second aspect, a modular construction block which includes a preform having a top, a bottom, opposite sides, and opposite ends, at least three intersecting passageways extending through the preform. The at least three intersecting passageways extend along three different planes.

[0008] The present invention provides, in a third aspect, a method for forming a floor which includes providing a first plurality of modular construction blocks, as described above, and a second plurality of modular construction blocks. The second plurality of modular construction blocks includes a preform having a top surface, a bottom surface, opposite side surfaces, opposite end surfaces, and a pair of spaced-apart horizontal passageways extending between the opposite side surfaces. At least one row of the first plurality of modular construction blocks is assembled in the second plurality of assembled modular construction blocks to define a girder. Thereafter, concrete is introduced into the passageways in the first and second plurality of modular construction blocks.

[0009] The present invention provides, in a fourth aspect, a method for forming a footing and a foundation. The method includes assembling a first plurality of modular construction blocks, as described above, end to end to form a perimeter of the foundation, and assembling a second plurality of modular construction blocks in the footing to form the foundation. The second plurality of modular construction blocks includes a preform having a top surface, a bottom surface, opposite side surfaces, and opposite end surfaces, and a pair of spaced-apart horizontal passageways extending between the opposite side surfaces. Concrete is then introduced into the passageways in the first and second plurality of modular construction blocks so that the concrete in the perimeter forms a grid pattern.

[0010] The present invention provides, in a fifth aspect, a method for forming a floor which includes assembling a plurality of modular construction blocks comprising a preform having a top surface, a bottom surface, opposite side surfaces, and opposite end surfaces. The preform includes a pair of spaced-apart horizontal passageways extending between the opposite side surfaces. Some of the passageways are opened to the top to form a trough. Thereafter, concrete is introduced into the passageways and troughs of the assembled plurality of modular construction blocks.

[0011] The present invention provides, in a sixth aspect, a furring strip for use with modular construction blocks having passageways which are assembled and filled with concrete. The furring strip includes an elongated member and a plurality of elongated anchors attachable to the elongated member. The elongated members have a plurality of outwardly-extending portions for engaging the modular construction block and for extending into the passageways.

[0012] The present invention provides, in a seventh aspect, a method for forming a wall which includes assembling a plurality of modular construction blocks comprising a preform having a top surface, a bottom surface, opposite side surfaces, opposite end surfaces, and a pair of spaced-apart vertical passageways extending between the top and bottom surfaces. A plurality of furring strips are installed against the assembled blocks. The plurality of furring strips comprise an elongated member and a plurality of elongated anchors attachable to the elongated member. The elongated member has a plurality of outwardly-extending portions for engaging the modular construction block and extending into the passageways. Thereafter, concrete is introduced into the passageways of the assembled plurality of modular construction blocks so a portion of the plurality of anchors is secured in the concrete.

[0013] Also, disclosed are kits comprising the various blocks and furring strips.

[0031] FIGS. 1, 3, 8, and 11 illustrate modular construction blocks in accordance with the present invention. As illustrated in FIGS. 1, 3, 8, and 11, the blocks include a preform and a plurality of passageways therethrough. The preforms may by formed from a plastic material and used by assembling and filling with concrete and steel reinforcing bars to form footings, foundations, girders, walls, and roofs. The modular construction blocks generally include a 5-hole block (and modified 5-hole block) which includes five holes or passageways extending therethrough and a 2-hole block (and modified 2-hole block) which includes two holes or passageways extending therethrough. As described in greater detail below, the combination of 5-hole blocks and 2-hole blocks results in forming reinforced cement or concrete within the blocks which has an interlocking grid configuration in one plane or axis, two planes or axes (e.g., wall and floor), and/or three planes or axes (e.g., floor, wall, and roof which strengthens the building structure.

[0032] With reference to FIGS. 1 and 2, a 5-hole modular construction block 10 generally includes a preform 20 having a top surface 21, a bottom surface 22 (FIG. 2), opposite side surfaces 23 and 24 (FIG. 2), and opposite end surfaces 25 (only one end surface being shown in FIG. 1).

[0033] A plurality of passageways extends through the preform. For example, the plurality of passageways intersects and extends along three different planes. As illustrated in FIGS. 1 and 2, a first horizontally-extending passageway 30 extends between and opens onto each of the opposite end surfaces. A pair of spaced-apart vertically-extending passageways 32 extends between and opens onto top surface 21 and bottom surface 22 (FIG. 2) and intersects first horizontally-extending passageway 30. A pair of spaced-apart second horizontally-extending passageways 34 extends between and opens onto the opposite side surfaces 23 and 24 and intersects first horizontally-extending passageway 30 and the pair of vertically-extending passageways 32.

[0034] With reference to FIGS. 3 and 4, a 2-hole modular construction block 50 generally includes a preform 60 having a top surface 61, a bottom surface 62 (FIG. 4), opposite side surfaces 63 and 64 (FIG. 4), and opposite end surfaces 65 (only one end surface shown in FIG. 3). As illustrated in FIGS. 3 and 4, a pair of spaced-apart second horizontally-extending passageways 74 extends between and opens onto the opposite side surfaces 63 and 64 (FIG. 4).

[0035] The blocks may also be provided with interlocking portions to aid in aligning and maintaining the blocks in position when assembled or stacked together. For example, the top surface and the bottom surface, the opposite side surfaces, and the opposite end surfaces may each include interlocking portions. FIGS. 1 and 3 illustrate one example of interlocking portions which includes indentations 40 disposed on side surface 23 of block 10 (and side surface 24 may include corresponding raised projections, not shown in FIG. 1). FIG. 3 illustrates an example of raised projections 80 disposed on surface 63 of block 50. It will be appreciated that the opposite surfaces, top surfaces, bottom surfaces, and end surfaces may also be provided with interlocking portions. When the blocks are assembled and/or stacked together, the ends of adjacent blocks may be staggered.

[0036] With reference still to FIGS. 1 and 3, the indentations and projections provide alignment in two directions or planes, e.g., up and down, and side-to-side. It will be appreciated that the raised portions and indentations may include other configurations such as raised and indented squares or circles. In addition, the raised portion and indentations may extend completely along the length or width of the block or around the openings. Other suitable interlocking portions for use with the blocks of the present invention are disclosed in U.S. Pat. No. 6,161,357 issued to Altemus, and U.S. Pat. No. 5,457,926 issued to Jensen. The entire subject matter of these patents is incorporated herein by reference.

[0037] FIGS. 5 and 6 illustrate a foundation 100 constructed using a plurality of blocks 10 and 50. A footing 110 of foundation 100 is constructed by stacking two rows of 5-hole blocks 10 in a standard run to form the perimeter of the foundation and laying a plurality of 2-hole blocks 50 within the perimeter. At intervals in the floor, two rows of 5-hole blocks 10 may be installed to form a girder 120 (FIG. 5). The blocks may be initially assembled and held together using an adhesive such as 3M's SUPER 77 adhesive.

[0038] With reference to FIG. 7, plugs 140 (only one of which is shown in FIG. 7) may have a slight taper and used to seal the bottom vertical opening in the blocks. The plugs may also be held and fastened to the block using an adhesive. The top openings which will be filled with concrete provide a solid structure for attachment or securing fasteners.

[0039] Steel reinforcement, for example, steel reinforcing bars 142 may be inserted into the blocks forming the foundation. Suitable spacer clips 144 and 146 may be used to support and maintain the steel reinforcing bars in the proper location within the blocks when introducing the concrete. As shown FIG. 7, spacer clips 144 and 146 may be a wire or plastic form having one or portions which engage one or more reinforcing rods. The ends of the clips may be sized to engage the inner surface of the passageways.

[0040] FIGS. 8 and 9 illustrate a modified 5-hole modular construction block 200. Block 200 may be used for footing, headers, and girders, and avoid the need for attaching plugs to the bottom openings. Block 200 generally includes a preform 220 having a top surface 221, a bottom surface 222 (FIG. 9), opposite side surfaces 223 and 224 (FIG. 9), and opposite end surfaces 225 (only one end surface shown in FIG. 8).

[0041] A plurality of passageways extends through the preform. For example, the plurality of passageways intersects and extends along three different planes. As illustrated in FIGS. 8 and 9, a first horizontally-extending passageway 230 extends between and opens onto each of the opposite end surfaces. A pair of spaced-apart vertically-extending passageways 232 extends between top surface 221 and opens into first horizontally-extending passageway 230 and do not extend onto bottom surface 222 as shown in FIG. 9. A pair of spaced-apart second horizontally-extending passageways 234 extends between and opens onto the opposite side surfaces 223 and 224 and intersects first horizontally-extending passageway 230 and the pair of vertically-extending passageways 232.

[0042] Blocks 10, 50, and 200 may be formed from plastic or polymeric material such as a foam plastic material. Such foam plastic materials may include dense polystyrene foam. The blocks may also include recycled materials, or combinations of virgin and recycled materials. It is also appreciated that the preforms may be formed from concrete, or cement or clay and used in forming hollow building structures or filled with cement and reinforcing bars.

[0043] The blocks may include the top surface, the bottom surface, and the opposite side surfaces defining a square cross-section, and the top surface, the bottom surface, and the opposite end surfaces may define a rectangular cross-section. For example, the blocks may be 24 inches long, 12 inches high, 12 inches wide, and the passageways may be cylindrical having a diameter of 6 inches. It will be appreciated that the blocks may be formed in other sizes and the passageways may have other configurations other than cylindrical. While the blocks have been described as having a top surface and bottom surface, it will also be appreciated that depending on the orientation of the block, the opposite side surfaces may be the top and bottom surfaces.

[0044] With reference again to FIG. 5, once the blocks are assembled and the reinforcing bars installed, holes 130 (only one of which is shown in FIG. 5) are cut in the center of the floor. Concrete may then be injected, using a tapered hose end which fits tightly in the hole. Alternatively, the concrete may be injected through the vertical openings in girder 120. The concrete may be a lightweight concrete and may incorporate recycled materials to increase strength and/or reduce weight. The concrete may be driven by a commercial concrete pump which supplies sufficient pressure to cause the concrete to flow through the passageways. When concrete is visible in the blocks forming the footing, the hose is removed, and the hole is sealed with a plug. Thereafter, the blocks forming the footing are filled with concrete.

[0045] FIG. 10 illustrates a wall 300 formed by stacking 2-hole blocks on the footing with the passageways therein disposed vertically. As discussed above, an adhesive may be used to hold the blocks in place. Doors headers (not shown) and window headers 310 (only one being shown in FIG. 10) are formed by stacking 2-hole blocks from the footing to the top of the desired window or door opening. Two rows of the 5-hole blocks, the lowermost vertical openings being plugged or the lower row of blocks being the modified 5-hole blocks, are then stacked to bridge the openings. Steal reinforcing bars may be inserted in the blocks. Thereafter, concrete can be injected into the passageways. Air vent holes may be required to allow the release of air when injecting the concrete into the walls.

[0046] Subsequent floors 320, as well as roofs 340, may require scaffolding in order to install and support the blocks when introducing the concrete as described above. Forming of roofs may also require cutting air vent holes prior to injecting the concrete into the blocks forming the roof.

[0047] Where the wall and roof intersect, both the top block of the wall and the lower blocks of the roof may be cut on an angle (e.g., ½ the pitch of the roof) to intersect so that the openings of the passageways align and through which the reinforcing bar and concrete can be introduced. Such a configuration forms a continuous joint along the intersection of the wall and roof.

[0048] FIGS. 11 and 12 illustrate a modified 2-hole block 400 in which top portions of the block have been removed to open and expose the horizontally-extending passageway to define and form a trough 474. When used in the floor or foundation, the removed portions are filled to the top of the blocks with concrete (and reinforcing bar) to strengthen the floor along a horizontal plane compared to the floor shown in FIG. 5. The increased strength may allow a floor to have a greater span between supports, columns, or bearing walls. While the modified 2-hole block may include removal of two portions, specific portions may be selected and removed, for example, on site. For example, FIG. 13 illustrates a floor 500 which includes alternating portions of the 2-hole blocks having portions removed. It will be appreciated that where added strength is needed, the two-hole blocks may be formed with troughs by a manufacturer, cut prior to assembly, or cut after assembly, and then filled with concrete and reinforcing bars.

[0049] In addition, an I-beam may be formed into a floor using blocks of the present invention. As shown in FIG. 14, a floor I-beam 600 may be formed by two stacked rows of 5-hole blocks. The block disposed below the floor may be provided with plugs on each of the lateral sides and bottom. Such a configuration may result in floors with greater spans or reduced need for support columns.

[0050] The footings, girders, and headers, I-beams being formed with the 5-hole blocks provide a grid, a lattice, or a crisscrossing and interconnecting pattern (e.g., ladder on side) resulting in added strength. In addition, footings formed with the 5-hole blocks have a grid in one plane which is connected the floor disposed in a second plane. Use of the modular construction blocks of the present invention results added strength to the structure in that the entire structure may be formed with a concrete and steel reinforced locked-in web or cage due to the grid formations resulting form assembly of the various blocks. In addition, the intersection of, for example, a wall to a floor, or a wall to a roof may be provided with two rows of 5-hole blocks to provide a grid in one or more planes.

[0051] The walls, floors, foundations, footings, and roofs may be covered with a suitable covering material such as plaster, stucco or other suitable material. Sheetrock may be glued to the inside of walls and floors may be glued in place. Radiant heat may be bonded to the floor before securing a finished floor above.

[0052] FIG. 15 illustrates a surface fastener or furring strip 700 for use in attaching other types of interior or exterior surfacing to the assembled blocks. Furring strip 700 generally includes an elongated member 710 and a plurality of anchors 720. Prior to introducing concrete into the various passageways in, for example a wall as shown in FIG. 16, a plurality of spaced-apart furring strips 700 may be positioned against the wall with the anchors pushed through the foam blocks. An end portion 722 of the anchors 720 may have outwardly extending portions such as spikes or barbs which attach and anchor to the concrete when cured, while the middle portion 724 may have outwardly extending portions such as spikes or barbs which engage and are retained in the foam portion of a block prior to the concrete being poured. Various finishing surfaces such as wood framing can be attached to the elongated member 710. The elongated member may be made from wood or plastic and may be sized three inches wide and 1¼ inches thick.

[0053] Such structures formed in accordance with the invention may be better able to withstand winds, tornados, or other natural forces. In addition, a structure such as a building may be formed or manufactured at a central or manufacturing site, and due to its grid-like interconnection of the concrete and reinforced bars, may be lifted and transported to a remote site for use. While the entire structure may be assembled and transported, smaller sections or portions may also be assembled and transported with final assembly at a desired location. For transporting, one or more attachment points such as attachment hooks or eyes may be incorporated into the structure to allow the structure to be lifted and transported. In addition, the building structure may be configured and include suitable devices to allow the structure to be buoyant, and thus, float in a body of water such as a lake or river. It will also be appreciated by those skilled in the art that various sizes of the blocks may be used. For example, for a shed, six inch blocks having three inch diameter passageways may be used.

[0054] Thus, while various embodiments of the present invention have been illustrated and described, it will be appreciated to those skilled in the art that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention.