Wall construction system and method

[0001] The present invention relates generally to the field of building construction systems and more particularly to a wall construction system and method.

[0002] We depend upon modern building construction to solve many of the problems of our daily lives. We expect our buildings to be much more energy-efficient than in the past. In addition, we value privacy and entertainment, so we want our buildings to complement those parts of our lifestyles. High-powered audio-visual and entertainment systems can easily be heard in adjacent rooms and throughout a house or other building. Office discussions are more frequently subject to eavesdropping and other privacy concerns. Sound-control is a top priority for many individuals and businesses. More and more is demanded of our buildings, whether office buildings and other commercial workplaces or homes.

[0003] Thus, what is desired is a wall construction system that provides superior thermal, acoustic and strength characteristics, and is also very simple to build.

[0004] A wall construction system includes a footer attached to a floor. A plurality of blocks, such as foam or plastic blocks, are stacked to create one or more walls. The shape of the blocks creates a series of vertical and horizontal channels through the stacked blocks. A plurality of vertical reinforcing bars are attached to the floor, and horizontal reinforcing bars are attached to the vertical reinforcing bars between the layers of blocks. Each block includes a plurality of longitudinal grooves that accept a plurality of joining strips to align the blocks and hold them in place. A plurality of lateral clips is attached to a pair of joining strips and across the top of each block, perpendicular to the longitudinal grooves. The entire assembly is filled with a quantity of concrete to envelope the horizontal and vertical reinforcing bars.

[0011] FIG. 1 shows a perspective view of a disassembled wall construction system. The foundation of the wall construction system is the footer 10. The footer 10 is placed against the floor and provides attachment points for the first layer of the wall. The footer 10 includes a pair of parallel U-shaped channels 14 that bare secured directly to the floor. The channels 14 can be a sheet metal stamping or other durable materials. The footer 10 can be angled or mitered to create corners or other features common to building and wall construction.

[0012] A plurality of vertical reinforcing bars 18 extend upward from the floor between the channels 14. The vertical bars 18 may be incorporated directly into the floor, such as a concrete slab, for maximum stability of the finished wall. The spacing of the vertical bars 18 can conform to local building codes or other conventions. For example, the spacing between the vertical bars 18 can be 16 inches.

[0013] The wall construction system includes a plurality of horizontal reinforcing bars 20, construction blocks 22, joining strips 30, and lateral clips 32.

[0014] FIG. 2 shows a perspective view of the wall construction system with a single block 22. A pair of vertical bars 18 are shown in FIG. 2, with a first layer of horizontal bars 20 attached to each of the vertical bars 18 above the footer 10. It is preferred that the horizontal bars 20 do not contact the footer 10 directly. Instead, the horizontal bars 20 are separated from the footer 10 with shims and then wired into place. When the horizontal bars 20 are properly secured to the vertical bars 18, the shims can be removed to provide a gap between the horizontal bars 20 and the footer 10.

[0015] FIG. 3 shows three blocks 22 creating a partially assembled wall. The plurality of blocks 22 in the first layer are placed into and onto the footer 10. The unique construction of the blocks 22 permits this arrangement. The blocks 22 have continuous channel or groove 34 around their top, bottom and sides. The major surfaces of the blocks 22 facing the outside of the wall are not contoured and are substantially smooth. Each block 22 also includes one or more vertical holes 24 completely contained within the block 22. A vertical half-hole 26 is located at the side edges that butt against other blocks 22. When the wall is assembled, the half-holes 26 are a part of the continuous channel 34 around each block 22. When a plurality of blocks 22 are formed into a layer, two half-holes 26 butt against each other to form one complete new vertical hole. The spacing between a vertical hole 24 and the adjacent vertical hole 24 or pair of half-holes 26 matches the spacing of the footer holes 16 and the vertical bars 18.

[0016] Each block 22 is placed onto the footer 10 so that the continuous channel or groove 34 around the block 22 is centered over and parallel to the footer 10. The horizontal bar 20 of the first layer is approximately centered between the blocks 22 and the footer 10. When the plurality of blocks 22 for the first layer is completed, a plurality of joining strips 30 are pressed into the longitudinal grooves 28 along the top and bottom edges of each block 22. The strips 30 can be a single piece of an extruded material or plastic or metal sheet that is unrolled and cut to length. A single strip 30 can run the entire length of the wall. Alternatively, precut strips 30 can be manufactured in standard lengths and packaged for use on the job site. The strips 30 are approximately twice as high as the depth of each longitudinal groove 28. Thus, about half of each strip 30 protrudes above the top of each block 22. Next, a plurality of lateral clips 32 are placed across the tops of each block 22 and attached to the parallel strips 30 to join the parallel strips 30 together. The plurality of lateral clips 32 form a bridge along the tops of the blocks 22 of that layer. A subsequent layer of horizontal bars 20 is placed across the plurality of lateral clips 32, against the vertical bars 18 and approximately centered between the strips 30. The lateral clips 32 suspend the horizontal bars 20 above the continuous channel 34 along the top of the plurality of blocks 22 so that the horizontal bars 20 can be easily secured to the vertical bars 18. Typically, only one lateral clip 32 is required between each vertical bar 18. The lateral clips 32 provide some lateral support of the joining strips 30 and also support the horizontal bars 20 until they are secured to the vertical bars 18.

[0017] When the horizontal bars 20 are secured to the vertical bars 18, that layer is finished and the wall is ready for the next layer of blocks 22. As explained earlier, each block 22 includes a number of longitudinal grooves 28 along the top and bottom edges. The blocks 22 of the next layer are pressed down onto the strips 30 protruding from the top of the blocks 22 in the previous layer. The blocks 22 are placed in a staggered formation atop the previous layer to minimize the number of seams that align, similar to common masonry construction. The blocks 22 are somewhat deformable, allowing the grooves 28 to accommodate the multiple layers and various thicknesses of strips 30 and clips 32.

[0018] The construction process continues with subsequent application of strips 30, clips 32, horizontal bars 20 and blocks 22 until the wall is the desired size. Electrical conduit, cables 40, plumbing and other materials may be incorporated into the wall as it is built. This eliminates the necessity of making holes in the blocks 22 after construction is completed.

[0019] Upon completion of the wall, the continuous horizontal and vertical channels 34 through and around the blocks 22 can be filled with a slurry of concrete, surrounding the horizontal bars 20 and vertical bars 18 with concrete and providing exceptional strength properties to the wall. The blocks 22 may be made from a lightweight foam, such as polystyrene, or other suitable materials. Such construction methods and materials result in a wall with outstanding acoustic and thermal insulation properties as well as exceptional strength. In addition, the blocks 22 may be made on the job site, eliminating the need to transport heavy bricks. The blocks 22 may be made in any desired length to minimize the number of vertical seams, or may be a standard size to simplify the manufacturing and construction process. The blocks 22 may also be made from multiple smaller blocks that are glued or bonded together.

[0020] FIGS. 4-6 are end and top views of partially assembled wall block 22 with the associated hardware. The block 22 has a generally H-shaped profile and includes a continuous channel 34 around the top, ends and bottom. The top and bottom parts of the channel 34 are visible in this view in FIGS. 4 and 5. The block engages the U-shaped channels 14 of the footer. The vertical bars 18 are shown incorporated directly into the floor 12. The block 22 is shown with four longitudinal grooves 28. FIG. 4 shows the upper two longitudinal grooves 28 with joining strips 30 inserted. The joining strips 30 are approximately twice the height of each longitudinal groove 28. A lateral strip 32 attaches across the top of the block to the two parallel joining strips 30. The lateral strip 30 provides a support position for a horizontal bar 20. In an assembled wall, the horizontal bar 20 is enclosed within the continuous channel 34.

[0021] FIG. 5 shows an end view of a disassembled wall block 22 with its associated hardware. Their proper orientation is shown. The vertical holes 24 include a vertical bar 18 that extends up from the footer 10. The vertical bars 18 are attached to the horizontal bars 20 at each of their intersections. FIG. 6 is a top view of an assembled block 22 for the wall system. The lateral clips 32 are shown beneath and supporting the horizontal bar 20.

[0022] While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alterations, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alterations, modifications, and variations in the appended claims.