Spacer system for glass block walls

Abstract

This application discloses a system and method for assembling glass block walls from straight and non-straight glass blocks using horizontal and vertical spacers. The horizontal spacer is shaped to fit a top or bottom surface of the glass block and has elongated tabs and receiving holes, which extend from opposing sides. The elongated tabs engage the receiving holes of adjacent horizontal spacers. The vertical spacers are positioned on a side surface of the glass block, and have a shape and a thickness that corresponds to the vertical space between adjacent glass blocks and engage the side surface.

Description

RELATED APPLICATIONS

[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/289,223, filed Nov. 7, 2002, and entitled HORIZONTAL SPACER TO FORM ANGLED GLASS BLOCK WALLS.

FIELD OF INVENTION

[0002] The present invention is directed toward the field of spacer systems for glass blocks. In particular, the present invention relates to horizontal and vertical spacers for positioning straight and non-straight glass blocks, which enables non-straight glass blocks to be connected to adjacent non-straight or straight glass blocks such that any configuration of wall may be formed using such blocks.

BACKGROUND OF THE INVENTION

[0003] Glass blocks are widely used in modern architecture and in the construction industry for building things such as walls, partitions and shower walls. The angle between the lateral interface surfaces or side surfaces of glass blocks may be 0 degrees (in the case of straight glass blocks), or 22½ degrees, 45 degrees, 90 degrees (in the case of non-straight glass blocks). Non-straight glass blocks may angled or in the case of radius blocks, curved outer faces. Straight and non-straight glass blocks have a raised peripheral flange around the edges of the inner and outer faces. The peripheral flanges define a cavity/groove on the top and bottom surfaces of the glass blocks. The shapes of the cavities are dependent on the shape of the glass block.

[0004] When assembling a glass block wall with mortar a high degree of skill is required, as the weight of the blocks on the mortar make it difficult to obtain evenly spaced horizontal or vertical course arrangements between each row of blocks. Also, the blocks tend to be non-porous and as a result do not form a strong bond with the mortar. In order to solve these problems, many glass block assemblies exist which use generally rigid spacing, reinforcement and tying devices for the blocks. However, many of these assemblies have a large number of parts, and/or require a skilled laborer to assemble the glass block wall.

[0005] As a consequence, there is a need for a spacer system for use with non-straight glass blocks that not only enables lateral alignment between the blocks to be easily obtained, but also allows the size of the joints to be adjusted. Further, there is a need for a spacer system for use with non-straight glass blocks that has a minimal number of parts such that the glass block wall may be constructed quickly and easily by an unskilled laborer, thereby reducing the cost. Accordingly, it is an object of the invention to provide a horizontal spacer for positioning straight or non-straight glass blocks, which fulfills these needs. It is a further object of the invention to provide a vertical spacer for positioning between non-straight and straight or non-straight glass blocks.

SUMMARY OF THE INVENTION

[0006] This present invention is a system and method for assembling glass block walls from straight and non-straight glass blocks using horizontal and vertical spacers. The horizontal spacer is shaped to fit a top or bottom surface of the glass block and has elongated tabs and receiving holes, which extend from opposing sides. The elongated tabs engage the receiving holes of adjacent horizontal spacers. The vertical spacers are positioned on a side surface of the glass block, and have a shape and a thickness that corresponds to the vertical space between adjacent glass blocks and engage the side surface.

[0007] Preferably, the horizontal spacer comprises a main portions that is positioned between the top and/or bottom surfaces of the non-straight glass block, and tabs which extend from opposing sides of the main portions. Receiving holes are also located on opposing sides of the main portion. The tabs connect to other non-straight horizontal spacers by inserting the tabs into the receiving holes of the adjacent horizontal spacer. The tabs can also connect to a straight horizontal spacer by inserting the tabs directly into the spacer. The tabs extend perpendicularly from an edge of the main portion, such that lateral alignment between adjacent glass blocks is easily obtained. Further, the tabs allow for the spacing between the joints to be adjustable.

[0008] The horizontal spacer may consist of two identical pieces. The main portion of each piece has pegholes and pegs, which connect the identical pieces together. Preferably, the tabs on one side of the main portion are diagonally opposite from the tabs on the other side, as are the receiving holes. Therefore, as the tabs are offset, two tabs and two receiving holes are located on opposing sides. Advantageously, parts are minimized as one piece of the horizontal spacer may be used under the first row of glass blocks, where a spacer of lesser thickness is required.

[0009] The vertical spacers may come in different shapes, depending on the type of glass blocks that are adjacent to each other.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Further features and advantages of the invention will be apparent from the following detailed description, given by way of example, of a preferred embodiment taken in conjunction with the accompanying drawings, wherein:

[0011] FIG. 1 is a perspective view of the horizontal spacer for use with radius glass blocks;

[0012] FIG. 2 is a perspective view of one half of the horizontal spacer for use with radius glass blocks;

[0013] FIG. 3 is a side view of the horizontal spacer for use with radius glass blocks;

[0014] FIG. 4 is a top view of the horizontal spacer for use with 90-degree glass blocks;

[0015] FIG. 5 is a perspective view of one half of the horizontal spacer for use with 90-degree glass blocks;

[0016] FIG. 6 is a perspective view of the horizontal spacer for use with 45-degree glass blocks;

[0017] FIG. 7 is a perspective view of one half of the horizontal spacer for use with 45-degree glass blocks;

[0018] FIG. 8 is a perspective view of the variable width vertical spacer;

[0019] FIG. 9 is a top view of the variable width vertical spacer between two radius glass blocks;

[0020] FIG. 10 is a top view of the variable width vertical spacer between a radius and a straight glass block;

[0021] FIG. 11 is a perspective view of the flat vertical spacer;

[0022] FIG. 12 is a top view of the flat vertical spacer for between 90-degree and straight glass blocks or 45-degree and straight glass blocks;

[0023] FIG. 13 is a perspective view of a section of glass block wall constructed in accordance with the teachings of this invention using the horizontal spacer for radius glass blocks;

[0024] FIG. 14 is a perspective view of the horizontal spacer for use with 90-degree glass blocks in use with adjacent straight glass blocks; and

[0025] FIG. 15 is a perspective view of the horizontal spacer for use with 45-degree glass blocks in use with adjacent straight glass blocks.

DETAILED DESCRIPTION OF THE INVENTION

[0026] Like numbers represent like parts in the figures.

[0027] Referring to FIG. 1, a perspective view of the horizontal spacer 10 for a radius glass block, such as the ARQUE® block by Pittsburgh-Corning Company, is shown. The horizontal spacer 10 is comprised of two identical main pieces 12, which fit together to form the horizontal spacer 10. Referring to FIG. 2, a perspective view of a main piece 12 of the horizontal spacer 10 having a radius shape is shown. Each main piece 12 includes an elongated tab 14 and receiving indent 16 on the opposing sides used to make the joint between glass blocks. Each main piece 12 also includes pegs 22 and pegholes 20. The pegs 22 of one main piece 12 fit into the pegholes 20 on another main piece 12 to secure the pieces 12 together to form the horizontal spacer 10 as shown in FIG. 1.

[0028] Referring to FIG. 3, a side view of the horizontal spacer 10 for a radius glass block is shown. The elongated tabs 14 are located diagonally to each other on opposing sides, as are the receiving indents 16 such that when the main pieces 12 are fitted together a receiving hole 17 is formed. The tabs 14 extend perpendicularly from the edge of main pieces 12 such that a square connection can be made to adjacent horizontal spacers, and therefore provide for lateral alignment. The tab 14 of one horizontal spacer will fit into the receiving hole 17 of an adjacent horizontal spacer. The tabs 14 include barbs 18 that aid in fitting the tabs 14 into corresponding receiving holes 17 of adjacent horizontal spacers of the system. The tabs 14 are insertably adjustable into the receiving holes 17 of adjacent straight or non-straight horizontal spacers. Therefore, the tabs 14 not only provide lateral alignment between adjacent glass blocks, but also allow the spacing between the joints of adjacent glass blocks to be varied. Tabs 14 may be broken off to get a smooth edge when the spacer 10 is abutting a wall or similar obstruction.

[0029] Ideally, the type of glass block used with the horizontal spacers of this system has a raised peripheral flange formed around the edges of the internal/external or front/back faces of the block. Between the raised peripheral flanges is formed a cavity or groove on the top and bottom surfaces of the glass blocks. As best shown in FIG. 3 the main pieces 12 have a raised portion 24 that is shaped to fit within the cavity defined by the peripheral flange.

[0030] Main pieces 12 have a radius shape to form horizontal spacer 10 for use with a radius glass block. However, the horizontal spacers of this system can come in any shape to accommodate any glass block. Further examples of shapes are shown in FIGS. 4 to 7.

[0031] Referring to FIG. 4, a perspective view of the horizontal spacer 26 for a 90 degree glass block, such as the HEDRON® corner block by Pittsburgh-Corning Company is shown. As best shown in FIG. 4 the raised portion 30 of the horizontal spacer is shaped to fit within the cavity defined by the peripheral flanges of a 90-degree glass block. Referring to FIG. 5, two identical main pieces 28 fit together to form the horizontal spacer 26 as shown in FIG. 4.

[0032] Referring to FIG. 6, a perspective view of the horizontal spacer 32 for a 45 degree glass block, such as the TRIDRON® 45 degree block units by Pittsburgh-Corning Company is shown. As best shown in FIG. 6 the raised portion 36 of the horizontal spacer is shaped to fit within the cavity defined by the peripheral flange of a 45-degree glass block. Referring to FIG. 7, a perspective view of a main piece 34 is shown which fits together with another main piece 34 to form the horizontal spacer 32 for a 45-degree block as shown in FIG. 6.

[0033] Referring to FIG. 8, a perspective view is shown of the vertical spacer 37 for positioning between the lateral interface surface of non-straight glass blocks, and between non-straight and straight glass blocks. Advantageously, the vertical spacer 37 has a wide portion 38 and narrow portion 40 such that the spacer may take the shape of the space between the blocks as shown in FIGS. 9 and 10. As shown in FIG. 9, the wide portion 38 of the vertical spacer 37 is positioned toward the curved or external side of the radius glass blocks 42 and the narrow portion 40 is located toward the straight or internal side of the radius glass blocks 42. Similarly, a top view of the vertical spacer 37 between a radius block 42 and straight glass block 44 is shown in FIG. 10, where the wide portion 38 is positioned toward the curved side of the radius glass block 42 and the narrow portion 40 is located toward the straight side of the radius glass block.

[0034] Referring to FIG. 11, a perspective view of a flat vertical spacer 54 is shown. The flat vertical spacer 54 has an indent 55. As shown in FIG. 12, indent 55 of vertical spacer 54 may be aligned with the intermediate peripheral flange 57 of the straight glass block 44 for positioning a straight glass block 44 against a non-straight glass block such as a 90-degree glass block 50, or 45-degree glass block 56.

[0035] Referring to FIG. 13, a perspective view of a glass block wall 58 is shown using horizontal spacers 10 with the radius glass blocks 42 and straight horizontal spacers 46 for straight glass blocks 44. Straight glass blocks 44 are available in various sizes from various commercial sources such as Pittsburgh-Corning Company. Vertical spacer 37 may be used between the radius glass blocks 42 and straight glass blocks 44. Once the horizontal spacers 10 and 46 are in place over the glass blocks 42 and 44 and the vertical spacers 37 are in place between the blocks, a new row of glass blocks may be placed on top of the glass blocks 42 and 44, and spacers 10 and 46. Vertical spacers may be put between the glass blocks of the new row. The method may be continued until the height desired for the glass block wall is obtained. The glass block wall 58 may be finished by filling the vertical and horizontal spaces between the glass blocks 42 and 44 with a suitable material such as mortar or silicone.

[0036] Between first and second rows of blocks, the raised portions 24, 30, and 36 of spacers 10, 26, and 32 are received by the cavities formed between the peripheral flanges on the tops of the first row of glass blocks, and the bottoms of the second row of glass blocks. However, only main pieces 12, 28 and 38 (i.e. one half of a spacer) are used when placed under the first row of glass blocks because there is only one cavity (i.e. on the bottom of the first row of glass blocks) to receive the raised portion 24, 30, and 36.

[0037] Referring to FIG. 14, a perspective view of a glass block wall 60 is shown using 90 degree horizontal spacer 26 with the 90 degree block 50 and straight horizontal spacers 46 for straight glass blocks 44. The raised portion 30 visible on top of the horizontal spacer 26 fits within the cavity defined by the peripheral flanges on the bottom of a 90-degree glass block 50, which will be placed over top of the spacer 26. The flat vertical spacer 54 are used to space the 90-degree block 50 and straight glass blocks 44.

[0038] Referring to FIG. 15, a perspective view of a glass block wall 62 is shown using a 45-degree horizontal spacer 32 with a 45-degree block 56 and straight horizontal spacers 46 for straight glass blocks 44. The raised portion 36 of the 45-degree horizontal spacer 32 fits within the cavity defined by the peripheral flanges on the bottom of a 45-degree glass block placed over top of the spacer 32. The flat vertical spacers 54 are used to space the 45-degree block 56 and straight glass blocks 44.

[0039] The three examples of horizontal spacers discussed herein are radius, 45 degree, and 90 degree; however, any shape of horizontal spacer can be formed to accommodate any straight or non-straight glass block. Further, although two tabs and two receiving holes are described as being on each of the main pieces 12, 28, and 34, more or less than two tabs or receiving holes may be used.

[0040] Preferably, only one elongated tab 14 will be positioned on main piece 12 of the horizontal spacer 10 with a radius shape, and one receiving indent 16 on an opposing side of the elongated tab 14 such that when two of the main pieces 12 are fitted together one elongated tab 14 and one receiving hole 17 will be found on each side of the horizontal spacer 10, rather than two elongated tabs 14 and two receiving holes 17 as shown in FIG. 1.

[0041] Accordingly, while this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments as fall within the true scope of the invention.

Claims

1. A system of spacers for assembling a glass block wall from a combination of non-straight and straight glass blocks, said system comprising:

a) horizontal spacers for positioning on one of a top and a bottom surface of said glass blocks, said horizontal spacers including:

i) a main portion shaped to match said one of said top and said bottom surface and to engage said surface;

ii) a first elongated tab extending from a first edge of said main portion, operative to engage a first adjacent horizontal spacer mounted on a first adjacent glass block; and

iii) a second elongated tab extending from a second edge of said main portion different from said first edge and operative to engage a second adjacent horizontal spacer mounted on a second adjacent glass block; and

b) vertical spacers for positioning on a side surface of said glass blocks, said vertical spacers having a shape and a thickness that corresponds to the vertical space between adjacent glass blocks and to engage said side surface.

2. The system of claim 1, wherein said first and second elongated tabs include barbs.

3. The system of claim 1, wherein said first and second adjacent horizontal spacers are straight horizontal spacers.

4. The system of claim 1, wherein said non-straight glass blocks include non-straight glass blocks of the following shapes: 90-degree, 45-degree, and radius.

5. The system of claim 1, wherein said main portion of said horizontal spacers is formed from two identical pieces.

6. The system of claim 5, wherein each of said two identical pieces further includes a plurality of male and female parts operative to guide said two identical pieces into opposed alignment.

7. The system of claim 5, wherein one of said identical pieces is operative to space a bottom row of said glass blocks.

8. The system of claim 1, wherein said first and second elongated tabs are perpendicular to said first and second edges, respectively.

9. The system of claim 1, wherein said first and second elongated tabs are insertable to an adjustable depth into receiving holes of said first and second adjacent horizontal spacers, respectively.

10. A system of spacers for assembling a glass block wall from a combination of non-straight and straight glass blocks, said system comprising:

a) horizontal spacers for positioning on one of a top and a bottom surface of said glass blocks, said horizontal spacers including:

i) a main portion shaped to match said one of said top and said bottom surface and to engage said surface;

ii) a first elongated tab extending from a first edge of said main portion, operative to engage a first adjacent horizontal spacer mounted on a first adjacent glass block;

iii) a first receiving hole located at said first edge of said main portion proximate said first elongated tab and operative to engage an elongated tab on said first adjacent horizontal spacer;

iv) a second elongated tab extending from a second edge of said main portion different from said first edge and operative to engage a second adjacent horizontal spacer mounted on a second adjacent glass block; and

v) a second receiving hole located at said second edge proximate said second elongated tab and operative to engage an elongated tab on said second adjacent horizontal spacer; and

b) vertical spacers for positioning on a side surface of said glass blocks, said vertical spacers having a shape and a thickness that corresponds to the vertical space between adjacent glass blocks and to engage said side surface.

11. The system of claim 10, wherein said first and second elongated tabs include barbs.

12. The system of claim 10, wherein said first and second adjacent horizontal spacers are selected from the group consisting of a horizontal spacer, and a straight horizontal spacer.

13. The system of claim 10, wherein said non-straight glass blocks include non-straight glass blocks of the following shapes: 90-degree, 45-degree, and radius.

14. The system of claim 10, wherein said main portion is formed from two identical pieces, each of said identical pieces containing an indent such that said two indents combine to form one of said receiving holes when said two identical pieces are joined together.

15. The system of claim 14, wherein each of said two identical pieces further includes a plurality of male and female parts operative to guide said two identical pieces into opposed alignment.

16. The system of claim 14, wherein one of said identical pieces is operative to space a bottom row of said glass blocks.

17. The system of claim 10, wherein said first and second elongated tabs are perpendicular to said first and second edges, respectively.

18. The system of claim 10, wherein said first and second elongated tabs are insertable to an adjustable depth into receiving holes of said first and second adjacent horizontal spacers, respectively.

19. A method of assembling a glass block wall from a combination of non-straight and straight glass blocks, said system comprising:

a) inserting horizontal spacers into horizontal spaces between adjacent glass blocks, said horizontal spacers being positioned on one of a top and a bottom surface of said glass blocks, and said horizontal spacers including:

i) a main portion shaped to match said one of said top and said bottom surface and to engage said surface;

ii) a first elongated tab extending from a first edge of said main portion, operative to engage a first adjacent horizontal spacer mounted on a first adjacent glass block; and

iii) a second elongated tab extending from a second edge of said main portion non-adjacent to said first edge operative to engage a second adjacent horizontal spacer mounted on a second adjacent glass block;

b) inserting vertical spacers into vertical spaces between adjacent glass blocks, said vertical spacers being positioned on a side surface of said glass blocks, said vertical spacers having a shape and a thickness that corresponds to the vertical space between adjacent glass blocks and to engage said side surface; and

c) applying a bonding agent in said horizontal spaces and in said vertical spacers to secure said glass blocks.

20. The method of claim 19, wherein said horizontal spacers further include:

a) a first receiving hole located at said first edge of said main portion proximate said first elongated tab and operative to engage an elongated tab on said first adjacent horizontal spacer; and

b) a second receiving hole located at said second edge proximate said second elongated tab and operative to engage an elongated tab on said second adjacent horizontal spacer.

21. The method of claim 19, wherein said first and second elongated tabs include barbs.

22. The method of claim 19, wherein said main portions of said horizontal spacers are sized to fit one of the following: a straight glass block, a 90-degree glass block, a 45-degree glass block, and a radius glass block.

23. The method of claim 20, wherein said main portion is formed from two identical pieces, each of said identical pieces containing an indent such that said two indents combine to form one of said receiving holes when said two identical pieces are joined together.

24. The method of claim 23, wherein each of said two identical pieces further includes a plurality of male and female parts operative to guide said two identical pieces into opposed alignment.

25. The method of claim 23, wherein said first and second elongated tabs are perpendicular to said first and second edges, respectively.

26. The method of claim 24, wherein first and second elongated tabs are insertably adjustable into receiving holes of said first and second adjacent horizontal spacers, respectively