Modular wall assembly apparatus and method

Abstract

An improved structural system of cooperating building components including premolded, interlocking block units having configurable interlocking components and passage configuration components. The block units are disposed end-to-end in a plurality of stacked, interlocking courses to form a configurable plurality of horizontal and vertical passageways for receiving material. The interlocking components and configuration components enable adjacent courses of the premolded block units to be vertically aligned and longitudinally interlocked. Horizontal passageways within a course are also configured for receiving material, for being fully closed to receiving material, or for being both partially closed to receiving a selected first material and partially open for receiving a selected second material, according to the orientation of the configuration and interlocking components.

Description

This application is entitled to and hereby claims the priority of co-pending U.S. Provisional application, Ser. No. 60/735,181 filed Nov. 10, 2005.

FIELD OF THE INVENTION

The present invention relates to a structural system of cooperating building components and modular wall assemblies constructed therefrom.

BACKGROUND OF THE INVENTION

Improvements of construction means and methods for building wall assemblies have a long history that defies simple classification. Accordingly, a practical taxonomy of wall assembly attributes is provided in Table 1 to distinguish novel features of the present invention from prior art.

TABLE 1
Wall Assembly Attributes
1.  Materials
2.  Sound
3.  Wind
4.  Thermal
5.  Moisture
6.  Fire Retardation
7.  Structural Configuration
8.  Layout Configuration
9.  Utility Network Configuration
10. Dimensional Integrity

Insulating concrete form (ICF) systems for wall assemblies comprise a recent art relative to means and methods for modular wall systems long known in the art of building construction. Prior art ICF systems are made of insulating foam and remain in place as a permanent part of a wall assembly, providing a continuous barrier having advantageous sound, wind, thermal, moisture, and fire retardation properties, as well as providing a backing for both interior finishes and exterior veneers. However, properties of prior art wall assemblies, components, and methods relating to materials, structural configuration, layout configuration, dimensional integrity, and installation vary significantly.

Broadly, prior art modular wall assemblies, components, and methods can be characterized as block systems or panel systems. Generally, block system units are factory premolded having interlocking means, comprising two finish surfaces and further comprising at least one cavity. Panel system units are factory premolded having edge interlocking means, comprising one finish surface. Pairs of panel system units are preassembled by various interconnecting means, forming at least one cavity, before being set in place. A plank system is a smaller variation of a panel system that can be assembled in place.

Within the broad categories of prior art modular wall assemblies, components, and methods, further subcategories are determined by properties relating to structural configuration of form cavities such as flat wall systems, grid wall systems, and post and beam systems. Flat wall systems are similar to a conventional monolithic concrete wall, providing a continuous thickness of metal-reinforced concrete. Grid wall systems provide a lattice-like structure, wherein the thickness of metal-reinforced concrete varies for some members, and are configured in a closely-spaced rectangular pattern. Post and beam systems have metal-reinforced concrete vertical posts, roughly corresponding to wall studs. The posts are laterally braced by at least one metal-reinforced concrete horizontal member, all of which are completely encapsulated in insulating foam, and which further cooperate to support a horizontal bond beam also formed from factory premolded block units having interlocking means and a recessed cavity adapted to receive metal-reinforced concrete.

DESCRIPTION OF THE PRIOR ART

Prior art teaches various systems of cooperating components and related methods for constructing static wall assemblies comprising mortarless, interlocking building blocks adapted, with varying degrees of success, to provide for flexible structural configurations responsive to a range of loading conditions and a plurality of layout configurations, while maintaining dimensional integrity. Prior art modular wall assemblies typically comprise dimensionally aligned form components that must not be displaced from direct vertical alignment in either horizontal direction.

Prior art mortarless, interlocking building blocks are generally adaptations of earlier modular wall assemblies comprising blocks made of various forms of cementitious material. U.S. Pat. No. 676,803, to Shaw, at lines 80-82 of col. 2, for example, teaches an edge interlocking configuration using tongues and grooves as shown in items 101 and 102 of FIG. 1. U.S. Pat. No. 3,552,076, to Gregori, U.S. Pat. No. 4,075,808, to Pearlman, U.S. Pat. No. 5,465,542, to Terry, and U.S. Pat. Nos. 5,899,040 and 6,244,009, to Cerrato all follow Shaw's edge interlocking configuration using tongues and grooves offset from a main block body, further shown in FIGS. 2-5. Referring to FIG. 4, it should be noted that only Terry's edge interlocking configuration using tongues and grooves provides vertical interlocking means capable of maintaining longitudinal dimensional integrity. The dimensional integrity of the other edge interlocking configurations cited above may be compromised when displaced longitudinally by sliding, for example.

Regarding various material properties taught in the art. U.S. Pat. No. 6,691,485 to Prokofyev, for example, teaches modular wall elements made from a material selected from the group consisting of cement, fiber-reinforced cement, wood, stone, ceramic, metal, gypsum, and plastic. Prior art further teaches a modular wall assembly system having at least one of its lower courses comprising modular block units molded from a first material having structural properties suitable for resisting lateral forces below grade due to hydrostatic pressure and the like. At least one of the above grade courses in the modular wall assembly system includes modular block units molded from a second lightweight insulating material.

Broadly, prior art teaches two types of vertical interlocking means for maintaining dimensional integrity in modular wall assemblies having interlocking building components. The first type of prior art vertical interlocking means is referred to herein as interlocking component and recess means, and the second type of prior art vertical interlocking means is referred to herein as interlocking projection and recess means for maintaining dimensional integrity in modular wall assemblies adapted for receiving poured or pumped concrete.

FIG. 6 shows an example of prior art interlocking key component 602 and recess 603 means as taught by U.S. Pat. No. 3,936,987 to Calvin, for dimensionally aligning vertically adjacent block units 601 in both horizontal directions. Accordingly, FIGS. 9A & 9B illustrate another example of prior art interlocking component and recess means as taught by U.S. Pat. No. 4,514,949 to Crespo. A plurality of metal balls 702 are placed in a first machined recess 703 in a first block 701 to dimensionally align a second block 701 by means of a juxtaposed second machined recess 703.

FIG. 13 illustrates yet another example of prior art interlocking key unit and key opening means as taught by U.S. Pat. No. 5,930,958 to Stanley for maintaining dimensional integrity in modular wall assemblies having block units adapted for receiving poured or pumped concrete. Stanley is an example of prior art teaching that lightweight ICF components, when insufficiently stabilized in both horizontal dimensions, may shift during concrete reinforcement due to the weight of the concrete, particularly in the lower courses. U.S. Pat. No. 3,552,076 to Gregori further teaches the need to stabilize ICF components from upward vertical displacement resulting from seepage of “liquid concrete” between forms by means of a deformable polymeric seal.

Table 2 associates FIGS. 4-17 with exemplary prior art interlocking projection and recess means for maintaining dimensional integrity in modular wall assemblies having block units adapted for receiving poured or pumped concrete. U.S. Pat. No. 4,439,967 to Dielenberg generally represents the utility, if not the novelty, of prior art interlocking projection and recess means for maintaining dimensional integrity in modular wall assemblies by interlocking adjacent top, bottom, and side surfaces of block units. U.S. Pat. Nos. 4,341,050, 5,024,035, and 6,065,265 to Long, Hanson, and Stenekes, respectively, have distinctive prior art interlocking projection and recess means for maintaining dimensional integrity as set forth below.

TABLE 2
Vertical Interlocking Means
U.S. Pat. No.           Fig. No.
3,936,987 to Calvin     6
4,341,050 to Long       7
4,439,967 to Dielenberg 8
4,514,949 to Crespo     9
4,894,969 to Horobin    10
5,024,035 to Hanson     11
5,421,135 to Stevens    12
5,465,542 to Terry      4
5,930,958 to Stanley    13
6,065,265 to Stenekes   14
6,244,009 to Cerrato    5
6,253,519B1 to Daniel   15
6,523,312 to Budge      16
6,691,481 to Schmidt    17

U.S. Pat. No. 4,341,050 to Long and U.S. Pat. No. 5,024,035 to Hanson provide exemplary positive interlocking and self-aligning means for adjacent courses which cooperate to encompass and thereby align the juxtaposed openings for adjacent vertical cavities, as shown in FIGS. 7 and 11.

U.S. Pat. No. 6,065,265 to Stenekes, while similar to other prior art projection and recess means for interlocking vertically adjacent surfaces of block units, has additional means to accommodate longitudinal metal reinforcement between adjacent courses. In a manner similar to Crespo, previously cited and shown in FIG. 9, FIG. 14 illustrates Stenekes' block 1401 with upwardly extending grooves 1403, 1404 formed in each recess 1402, for receiving metal reinforcement longitudinally in parallel to wall assembly surfaces.

Table 3 lists exemplary prior art related to structural configuration properties of modular wall assemblies having block units adapted for receiving poured or pumped concrete.

U.S. Pat. No. 5,024,035 to Hanson, et al., teaches a method long known in the art for selectively configuring encapsulated vertical passageways which are not to be used as forms for reinforced concrete. According to Hanson, et al., prior to pouring, “squares of cardboard or any other convenient material” are placed over encapsulated vertical passageways where concrete reinforcement is not wanted.

The prior art citations listed in Table 3 provide various means for selectively configuring encapsulated longitudinal and vertical passageways as forms for reinforced concrete. U.S. Pat. No. 4,439,967 to Dielenberg and U.S. Pat. No. 4,894,969 to Horobin provide configurable transverse means 804, 1004, which can be used to either terminate or extend the formation of longitudinal reinforced concrete members, see FIGS. 8 & 10. U.S. Pat. No. 6,922,962 to Schmidt (FIG. 17) provides for structural configuration by means of an optional bulkhead member used to terminate an insulated wall assembly to accommodate various layout configurations, which may include utility passage ways, door and window openings, and the like.

TABLE 3
Means To Selectively Fill Passages
4,439,967 to Dielenberg
4,894,969 to Horobin
6,922,962 to Schmidt

U.S. Pat. No. 4,075,808 to Pearlman, following Shaw's edge interlocking configuration referenced above, teaches an exemplary prior art modular system for wall assemblies having a plurality of interlocking block elements premolded of various “convenient” materials. The block elements, which permit a plurality of layout configurations, include full blocks, half blocks, adaptor blocks, corner blocks, wall end blocks, and interior wall connecting blocks.

According to Pearlman, the block elements typically include a main body having a pair of opposite, longitudinal side faces; a pair of lateral, opposite, side faces; and a pair of opposite, top and bottom faces, all of which are substantially parallel. It should be noted that block elements taught by Pearlman, as well as others that include a first partial, vertical passage completed by a second symmetrically-opposing, partial, vertical passage of an adjoining block, are subject to longitudinal separation under certain conditions, thereby compromising the dimensional integrity of a resulting wall assembly. It should be further noted that block elements taught by Pearlman and others, other than corner blocks, have no vertical interlocking means for preventing longitudinal shifting in certain loading conditions, thereby further compromising the dimensional integrity of a wall assembly.

Other drawbacks demonstrated by prior art ICF systems include impact on design resulting from the prefabricated dimensions and sizes of the block units which may not allow for or support particular configurations within the building design. Prior art ICF systems also have a higher initial cost and often do not conform with existing prescriptive methods.

SUMMARY OF THE INVENTION

In view of the foregoing, the present invention teaches a system of configurable structural components that embodies improvements relating to materials, structural configuration, dimensional integrity, utility network configuration and layout configuration of modular wall assemblies for erecting a complete structure.

More particularly, the present invention is directed to an improved system of configurable structural components in a modular wall assembly. The structural components include a plurality of factory premolded block units having improved interlocking components and configurable passageways for forming a post and beam or lattice-like structure having metal-reinforced concrete posts that are laterally braced by at least one metal-reinforced concrete horizontal member. These block units, having similar interlocking components and similar passage configuration components, are premolded from materials having various structural properties, with corresponding sizes of the block units being determined by the material properties for constructing complete wall assemblies which extend both above and below ground level.

A principal objective of the present invention is to provide an improved structural system of cooperating building components for modular wall units having a structural configuration which, responsive to a range of loading conditions, is adapted to use the fewest possible number of structural components, thereby minimizing material resource requirements.

Another objective of the present invention is to provide an improved structural system of cooperating building components for modular wall units having an improved vertical interlocking component adapted to prevent longitudinal shifting in certain loading conditions for enhanced stability in dimensional configuration.

Yet another objective of the present invention is to provide an improved structural system of cooperating building components for modular wall units having an improved utility network configuration adapted to controllably position utility network components in a vertical passage that intersects encapsulated horizontal structural components, thereby avoiding spatial conflict between the utility network configuration and the structural components.

A further object of the invention is to provide a plurality of modular block configurations having particular layout configuration features for interlocking adjoining modular blocks within a course, the course selected from a plurality of possible paths, wherein all the modular block configurations are sized having a fixed dimensional increment which is determined by a standard, center-to-center interval between vertical passages, thereby providing a plurality of possible wall assembly paths.

A still further object of the present invention is to provide an improved structural system of cooperating building components for modular wall units that minimizes impact on design while facilitating conformance to prescriptive methods.

Yet another object of the present invention is to provide an improved structural system of cooperating building components for modular wall units that is strong, durable and energy efficient with good thermal mass, noise abatement and low temperature installation characteristics.

A further object of the present invention is to provide an improved structural system of cooperating building components for modular wall units that requires fewer subcontracting and installation steps, while also reducing material requirements and their associated costs.

These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout. While the drawings are intended to illustrate the invention, they are not necessarily to scale.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a conventional edge interlocking configuration according to U.S. Pat. No. 676,803 to Shaw.

FIG. 2 shows another conventional edge interlocking configuration according to U.S. Pat. No. 3,552,076 to Gregori.

FIGS. 3A & 3B depict a further conventional edge interlocking configuration according to U.S. Pat. No. 4,075,808 to Pearlman.

FIG. 4 shows another conventional edge interlocking configuration according to U.S. Pat. No. 5,465,542 to Terry.

FIG. 5 depicts a still further conventional edge interlocking configuration according to U.S. Pat. No. 6,244,009 to Cerrato.

FIG. 6 illustrates a prior art interlocking key component and recess means of U.S. Pat. No. 3,936,987 to Calvin.

FIG. 7 illustrates a prior art interlocking key component and recess means of U.S. Pat. No. 4,341,050 to Long.

FIG. 8 illustrates a prior art interlocking key component and recess means of U.S. Pat. No. 4,439,967 to Dielenberg.

FIGS. 9A & 9B illustrate a prior art interlocking key component and recess means of U.S. Pat. No. 4,514,949 to Crespo.

FIG. 10 illustrates a prior art interlocking key component and recess means to U.S. Pat. No. 4,894,969 to Horobin.

FIGS. 11A & 11B illustrate a prior art interlocking key component and recess means of U.S. Pat. No. 5,024,035 to Hanson.

FIGS. 12A & 12B illustrate a prior art interlocking key component and recess means of U.S. Pat. No. 5,421,135 to Stevens.

FIG. 13 illustrates a prior art interlocking key component and recess means of U.S. Pat. No. 5,930,958 to Stanley.

FIGS. 14A & 14B illustrate a prior art interlocking key component and recess means of U.S. Pat. No. 6,065,265 to Stenekes.

FIG. 15 illustrates a prior art interlocking key component and recess means of U.S. Pat. No. 6,253,519B1 to Daniel.

FIG. 16 illustrates an additional prior art interlocking key component and recess means of U.S. Pat. No. 6,523,312 to Budge.

FIG. 17 illustrates a prior art interlocking key component and recess means of U.S. Pat. No. 6,691,481 to Schmidt.

FIG. 18 illustrates elements of a modular wall assembly, showing an improved system of cooperating building components, according to the present invention.

FIG. 19A shows the vertical interlocking component of FIG. 18 in the open orientation.

FIG. 19B shows the vertical interlocking of component of FIG. 19A rotated to the closed orientation in accordance with the present invention.

FIG. 20 illustrates various orientations of the aperture in the second configuration component of FIG. 18.

FIG. 21A illustrates a standard modular block form with interlocking components in accordance with the present invention.

FIG. 21B illustrates a U-block form with horizontal passageways configured for engagement with the block form of FIG. 21A.

FIG. 22A shows a corner block unit in accordance with the present invention.

FIG. 22B shows another corner block unit in accordance with the present invention.

FIG. 22C shows another corner block unit in accordance with the present invention.

FIG. 23 illustrates a layout configuration for corner block units in accordance with the present invention.

FIG. 24 is a perspective view of the corner block units of FIG. 23.

FIG. 25 illustrates angular corner block units in accordance with the present invention.

FIG. 26 is a top view of a layout with the angular corner block units of FIG. 25.

FIG. 27 illustrates an adapter block unit having identical longitudinal block orientations in accordance with the present invention.

FIG. 28 illustrates terminal block units having a single longitudinal block orientation for terminating a wall assembly in accordance with the present invention.

FIG. 29 shows junction block units for joining horizontally adjacent block units to perpendicularly disposed block units in accordance with the present invention.

FIG. 30 is a perspective view of a layout with the junction block units of FIG. 29.

FIG. 31A illustrates an exemplary wall assembly of the present invention.

FIG. 31B shows the wall assembly of FIG. 31A with an improved system of cooperating building components.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

FIG. 18 illustrates elements of a modular wall assembly in accordance with the present invention, showing an improved system of cooperating building components. The elements include a first premolded, interlocking block unit 1801 and a second premolded, interlocking block unit 1803 having interlocking components 1805 and configuration components 1812, 1812′. The block units are disposed end-to-end in a plurality of stacked, interlocking courses to form a configurable plurality of vertical and horizontal passageways 1802, 1804, 1809, 1810 for receiving reinforcement material. Such reinforcement material may include cementitious material, metal reinforcement members such as rebar, steel beams, and various combinations of these and other similar materials as would be known by persons of ordinary skill in the art. By filling various ones of the vertical 1802, 1804 and horizontal passageways 1809, 1810 with appropriate reinforcement materials, the blocks thereby form a post and beam or lattice-like structure. This is most commonly effected using metal-reinforced concrete posts that are laterally braced by at least one metal-reinforced concrete horizontal member.

Broadly, the present invention uses the interlocking and configuration components 1805, 1812, 1812′ to vertically align adjacent courses of the premolded block units, to longitudinally interlock the premolded block units within a course, and to configure selected horizontal passageways within a course for receiving material. A particular passage may be configured to be open for receiving material, fully closed to receiving material, or both partially closed to receiving a selected first material and partially open for receiving a selected second material. These alternative configurations provide improved control of the quantity of the selected material and further provide improved control of the configuration of the selected material.

Subsequent to the steps of using the improved configuration components to selectively configure the passageways for receiving material, the material is introduced into the selectively configured plurality of horizontal and vertical passages. For example, concrete posts are formed by pouring cementitious material into vertical passageways 1802, 1804, either with or without metal reinforcement, while horizontal reinforcement members such as rebar may be laid to pass through horizontal passageways 1810. A steel beam laid within horizontal passageways 1809 can be included to provide more substantive structural reinforcement.

Referring now to FIG. 18 in greater detail, first and second modular block units 1801, 1803 are shown vertically disposed in opposing longitudinal directions, representing adjacent courses in a modular wall assembly. Broadly, a first modular block unit 1801 is shown having a first vertical passageway 1802 and a first horizontal passageway 1809 for forming extended passageways when juxtaposed with adjacent modular block units. A second modular block unit 1803 is shown having a second vertical passageway 1804 aligned with the first vertical passageway 1802 to form such an extended passageway for receiving reinforced cementitious material. FIG. 18 further shows the second block 1803 having a second horizontal passageway 1810 for receiving metal reinforcement members such as rebar in a manner known in the art and illustrated in the prior art modular block unit 1401 of FIG. 14A.

The present invention includes a configurable, vertically interlocking component 1805 with a generally symmetrical frame 1818 having two opposing channels 1808 in opposite frame walls 1819. The height of the frame walls is such that, when the interlocking component 1805 is juxtaposed between a first interlocking recess 1806 in the first block 1801 and a second interlocking recess 1807 in the second block 1803, the upper portion of the wall is received in the first recess 1806 and the lower portion of the wall is received in the second recess 1807. As a result, the vertically interlocking component 1805 not only vertically aligns adjacent courses of the premolded block units 1801, 1803, but also longitudinally interlocks the premolded block units within a course. The latter prevents longitudinal slippage which is known in the art to be a problem associated with modular block units premolded from lightweight insulating materials.

The two opposing channels 1808 define an open orientation and a closed orientation for the frame 1818, as shown in FIGS. 19A and 19B, respectively. When positioned in the second interlocking recess 1807 in the open orientation shown in FIGS. 18 and 19A, channels 1808 align with passageways 1810 in the block unit 1803 for receiving metal reinforcement members therethrough. In such open orientation, but in the absence of metal reinforcement members, channels 1808 and passageways 1810 are subject to seepage of cementitious material from adjacent vertical passageways, potentially compromising the dimensional integrity between courses, particularly in lower courses of modular block units premolded from a lightweight insulating material. To solve this potential problem, the configurable, interlocking component 1805 may be positioned in the second interlocking recess 1807 in the closed orientation as shown in FIG. 19B. In the closed orientation, channels 1808 are orthogonal to passageways 1810, providing an effective “seal” of the vertical passageways to prevent seepage to adjacent vertical passageways. Hence, with the present invention, both horizontally reinforced and vertically separated configurations can be supported by rotating the interlocking component between the open and closed orientations.

While the cross-sectional shape of the vertical passageways 1802, 1804, interlocking components 1805, and the interlocking recesses 1806, 1807 are shown as squares, this is for illustrative purposes only. The shape could be circular or any regular polygon that allows the interlocking component 1805 to have a pair of opposing channels so as to be positioned in either open or closed orientations for receiving or being closed to metal reinforcement members.

Broadly, the various modular block unit configurations of the present invention have two forms: a first form 1803 is used in courses not having horizontal passageways 1809 for receiving reinforcement and/or cementitious material; and a second form 1801 is used in a plurality of courses having horizontal passageways for receiving reinforced cementitious material. The second form is referred to in the art as a “U” block.

It should be noted that the various modular block unit configurations are sized having a fixed dimensional increment. The increment is determined by a standard, center-to-center interval between vertical passageways for configuring the horizontal passageways to receive reinforced cementitious material in a manner responsive to a range of structural loading conditions. The block component face corresponding to a wall surface is premolded to have a plurality of vertical grooves 1814 corresponding to the center-to-center interval between the vertical passageways. Accordingly, the grooves 1814 are formed on the block component face parallel to the centerline of the vertical passage, thereby providing means for designating a line of attachment to an encapsulated structural component.

A first structural configuration component 1812 for configuring the horizontal passageways 1809 for receiving reinforced cementitious material is shown in FIG. 18. As shown, the configuration component 1812 has a solid face 1822 and an outer perimeter that fits complementarily with the shape of an interlocking recess 1811 in the “U” block 1801 that receives the component 1812. The configuration component 1812 is selectively positioned in the interlocking recess 1811 in the “U” block 1801, such that vertical passageways 1802 for receiving reinforced cementitious material are closed while horizontal passageways 1809 can receive and contain such material, thereby providing improved control of both the quantity of the reinforced cementitious material and the configuration of the material. Conversely, configuration components 1812 can be omitted in those recesses 1811 defining vertical passageways 1802, 1804 that are to receive reinforced cementitious material to form posts. In this way, concrete being poured into the wall structure can be limited to the desired passageways only, avoiding waste as well as interference from undesired concrete seepage into surrounding areas when concrete is not controlled/contained.

Alternatively, a second structural configuration component 1812′ for configuring the horizontal passageways for receiving both reinforced cementitious material and utility network components is also shown in FIG. 18. The configuration component 1812′ has a face 1823 with an aperture 1815 and, like the first component 1812, is selectively positioned in an interlocking recess 1811 in the “U” block 1801, such that vertical passageways 1802, 1804 for receiving reinforced cementitious material are closed. When the second configuration component 1812′ is used in place of the first configuration component 1812, however, a vertically oriented sleeve 1813 is fitted in the aperture 1815. The sleeve provides a conduit for receiving utility network components such as electrical lines, phone lines, cable lines, etc. With the sleeve 1813, any kind of wire or lines can be guided through the block wall while being fully separated from the concrete or other material poured in the passageway around the sleeve. The configuration component 1812′ is further capable of being positioned in a plurality of orthogonal configurations, as representatively shown in FIG. 20, to direct the utility network components as desired, such as away from metal reinforcement members.

As noted in connection with the interlocking components, the cross-sectional shape of the vertical passageways 1802, 1804, configuration components 1812, 1812′, and the interlocking recess 1811 are shown as squares for illustrative purposes only. The shape could be circular or any regular polygon that allows the configuration components 1812, 1812′ to be positioned in a plurality of orientations for blocking the vertical flow of reinforced cementitious material and, optionally, receiving and configuring the placement of the utility network components.

It should be noted that FIG. 18 further illustrates a feature of the present invention wherein corresponding sizes of the block units are determined by material properties for constructing complete wall assemblies which extend both above and below ground level. Accordingly, the below grade courses 1801 of the modular wall assembly of FIG. 18 further include modular block units molded from a material having structural properties suitable for resisting lateral forces due to hydrostatic pressure and the like. Hence, a first size is determined for the below grade modular block units. Similarly, the above grade courses 1802 of the modular wall assembly of FIG. 18 further include modular block units molded from a lightweight insulating material, such that a second size is determined for the above grade modular block units.

FIGS. 21-27 illustrate the system of block units of the present invention for flexible layout configuration of modular wall assemblies and for erecting a complete structure. As an overview, these block units include standard blocks 1901, 1905, 2101, 2104, 2203, 2204, 2503, 2504; corner blocks 2001, 2002, 2003; angular corner blocks 2201, 2202, 2302, 2303; an adapter block 2301; junction blocks 2501, 2502 and terminal blocks 2401, 2402. Together, the system of block units, interlocking components, structural configuration components, and utility network alignment components cooperate to produce improved modular layout configurations for complete wall assemblies.

The interlocking components overlap the vertical and longitudinal planes of adjoining modular block units of FIGS. 21-27, forming at least one vertical and at least one longitudinal projection and a corresponding vertical and longitudinal recess. The projection and corresponding recess have a size and shape ensuring insertion and interlocking, thereby providing an uninterrupted sound, wind, thermal, and moisture barrier at all joints between said adjoining modular block units. The interlocking components also provide a particular vertical and longitudinal block orientation.

As previously discussed in connection with FIG. 18, each of the modular block units of FIGS. 21-27 have a first form and a second form. The first form is referred to herein as a “block form” 1901, 2002, 2003 and the second form is referred to herein as a “U-block” form 1905, 2001. The “U-block” form 1905, 2001 includes horizontal passageways 1906, 2004 for receiving reinforced cementitious material or utility network components.

FIGS. 21A and 21B illustrate a standard modular block form 1901 and “U-block” form 1905 of the present invention comprising improved interlocking components 1904. The interlocking components 1904 provide vertical alignment between courses to provide longitudinal dimensional integrity, thereby ensuring vertical alignment for structural configuration components and utility network alignment components. It should be noted that the circular recessed interlocking components 1904 of FIG. 21A are substantially equivalent to the square interlocking components 1805 of FIG. 18, described above. The “U-block” form 1905 further includes horizontal passageways 1906 for receiving reinforced cementitious material. The modular block units 1901, 1905 of FIGS. 21A and 21B are further shown having a plurality of vertical passageways 1902, 1903.

FIGS. 22A, 22B and 22C illustrate different corner blocks in accordance with the present invention. FIGS. 22B and 22C illustrate a symmetrical first corner block unit 2002 and a symmetrical second corner block unit 2003, respectively, for joining horizontally adjacent block units disposed perpendicularly. The first and second corner block units 2002, 2003 have opposing (i.e., left/right) longitudinal block orientations, whereby the first and second corner block units 2002, 2003 allow adjacent block courses to traverse alternating longitudinal directions, thereby laterally offsetting vertical joints between adjacent block courses and improving the layout configurability of the modular wall assembly. Furthermore, FIGS. 22B and 22C illustrate the first “block” form in corner units 2002, 2003. FIG. 22A, on the other hand, shows a block unit representing the second “U-block” form in corner block 2001, wherein the “U-block” form 2001 further includes horizontal passageways 2004 for receiving reinforced cementitious material.

FIG. 23 illustrates layout configurations for symmetrical first and second corner block units 2102, 2103. The corner block units 2102, 2103 are shown connecting 2105, 2106 to adjacent standard modular block units 2101, 2104, described above. It should be noted that FIG. 23 further illustrates opposing longitudinal block orientations 2107 for the corner block units 2102, 2103. The cross symbol 2108, i.e., “+,” illustrates a center point for vertical passageways encapsulated in longitudinally adjacent modular block units 2101, 2102, 2103, 2104, with the block units being arranged in a linear course of a wall assembly. A representative perspective view of block units 2101, 2102, 2103, 2104 in adjacent block courses is shown in FIG. 24.

FIG. 25 illustrates symmetrical first and second angular corner block units 2201, 2202 for joining horizontally adjacent block units 2203, 2204 disposed to one another at an acute angle other than perpendicular. The first and second angular corner block units 2201, 2202 have opposing longitudinal block orientations, whereby the first and second angular corner block units allow adjacent block courses to traverse alternating longitudinal directions, thereby laterally offsetting vertical joints between adjacent block courses and improving layout configurability of the modular wall assembly. A representative top view of a block course with angular corner block units is provided in FIG. 26.

FIG. 27 illustrates an adapter block unit 2301 having identical longitudinal block orientations, (i.e., male-to-male or female-to-female), wherein longitudinally adjacent blocks 2302, 2303 having opposing longitudinal directions 2304 are joined, thereby improving layout configurability of the modular wall assembly.

FIG. 28 illustrates first and second terminal block units 2401, 2402 having a single longitudinal block orientation for terminating a wall assembly. Using such terminal block units 2401, 2402, longitudinally adjacent block courses are joined and terminated, thereby improving layout configurability of the modular wall assembly. It should be noted that the first terminal block 2401 is one modular interval greater in length than the second terminal block unit 2402, thereby accounting for offset joints in vertically adjacent courses, allowing alternating courses in a wall assembly segment to terminate in a vertical plane.

FIG. 29 illustrates symmetrical first and second junction block units 2501, 2502 for joining horizontally adjacent block units 2503, 2504 to perpendicularly disposed block units 2505, 2507. The first and second junction block units 2501, 2502 have opposing longitudinal block orientations, whereby the first junction block 2501 is one modular interval greater in length than the second junction block unit 2502. This difference in length enables offset joints in vertically adjacent courses to be accounted for, allowing alternating courses in a perpendicularly disposed wall assembly segment 2505, 2507 to terminate in a vertical plane. A representative perspective view of junction block units joining horizontally adjacent block units to perpendicularly disposed block units is provided in FIG. 30.

FIG. 31A shows an exemplary wall assembly 2601, 2602 of the present invention and FIG. 31B further shows an improved structural system of cooperating building components 2603, 2604. FIG. 31A illustrates a modular wall assembly system including a system of modular block units wherein at least one of its above grade courses 2602 includes modular block units molded from a lightweight insulating material. FIG. 31B illustrates a modular wall assembly system having a system of modular block units wherein at least one of its below grade courses 2603 includes modular block units molded from a material having structural properties suitable for resisting lateral forces due to hydrostatic pressure and the like.

The invention being thus described, it will be apparent that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be recognized by one skilled in the art are intended to be included within the scope of the following claims.

Claims

1. A modular wall assembly having a structural system of cooperating building components comprising:

a plurality of premolded block units disposed end-to-end in a plurality of stacked, interlocking courses to form a configurable plurality of horizontal and vertical passageways for receiving material;

configurable, interlocking components to vertically align adjacent courses of said premolded block units, to longitudinally interlock said premolded block units within a course, and to configure selected horizontal passageways for receiving material; and

passage configuration components to configure selected vertical passageways for receiving material, a particular passage being configured to be open for receiving material, fully closed to receiving material, or partially closed to receiving a selected first material and partially open for receiving a selected second material, thereby providing improved control of selected material quantity and configuration.

2. A method of constructing a structural system of cooperating building components having a plurality of premolded, interlocking block units, said method comprising the steps of:

assembling a plurality of premolded block units disposed end-to-end in a plurality of stacked, interlocking courses to form a configurable plurality of horizontal and vertical passageways for receiving material;

selectively configuring said plurality of horizontal and vertical passageways for receiving material using configuration components such that a particular passage is configured to be open for receiving material, fully closed to receiving material, or both partially closed to receiving a selected first material and partially open for receiving a selected second material, thereby selectively controlling both selected material quantity and configuration; and

introducing at least one of said materials into said selectively configured plurality of horizontal and vertical passages.

3. A modular wall assembly having a structural system of cooperating building components comprising:

(a) a standard block;

(b) a corner block;

(c) an angular corner block;

(d) an adapter block,;

(e) a junction block;

(f) a terminal block;

(g) vertical, lateral, and longitudinal interlocking components;

(h) structural configuration components; and

(i) utility network alignment components;

said system of block units, interlocking components, structural configuration components, and utility network alignment components cooperating with one another to produce improved modular layout configurations for complete wall assemblies.

4. The system of block units of claim 1, wherein said interlocking components overlap the vertical and longitudinal planes of adjoining modular block units to form at least one vertical and at least one longitudinal projection and a corresponding vertical and longitudinal recess, said projection and corresponding recess having a size and shape ensuring insertion and interlocking, thereby providing an uninterrupted sound, wind, thermal, and moisture barrier at all joints between said adjoining modular block units and said interlocking components further providing a particular vertical and longitudinal block orientation.

5. The modular wall assembly system of claim 1, wherein said plurality of premolded block units includes a standard modular block unit and said interlocking components include vertical alignment components between courses to provide longitudinal dimensional integrity, thereby ensuring vertical alignment for structural configuration components and utility network alignment components.

6. The vertical alignment components of claim 1, wherein said interlocking components and said configuration components include vertical alignment components, said vertical alignment components further including premolded interlocking projection and recess components integral to said modular block units.

7. The modular wall assembly system of claim 1, wherein said plurality of premolded block units includes structural configuration components that have at least one vertical passage extending through said premolded block units for alternatively encapsulating reinforced cementitious material, encapsulating utility network components, or encapsulating entrained, insulating air.

8. The system of block units of claim 1, wherein said system of block units is adapted to provide a configurable, recessed cavity for horizontally encapsulating any configuration of structural components and utility network alignment components, including the horizontal flow of fluid cement pumped or poured inside a modular wall assembly.

9. The system of block units of claim 1, wherein said system of block units includes structural configuration components that have a vertical passage closure component and premolded recess components, whereby said premolded recess components are integral to said standard modular block unit, thereby providing structural configuration components to selectively configure encapsulated vertical passageways for receiving reinforced cementitious material.

10. The modular wall assembly system of claim 1, wherein said system of block units includes utility network alignment components that have a configurable, vertical passage alignment component and premolded recess components, whereby said premolded recess components are integral to said standard modular block unit, thereby preventing obstruction of said vertical passage for said utility network.

11. The modular wall assembly system of claim 1, wherein said system of block units includes symmetrical first and second corner block units for joining horizontally adjacent block units disposed perpendicularly, said first and second corner block units having opposing longitudinal block orientations, whereby said first and second corner block units allow adjacent block courses to traverse alternating longitudinal directions, thereby laterally offsetting vertical joints between adjacent block courses and improving layout configurability of said modular wall assembly.

12. The modular wall assembly system of claim 1, wherein said system of block units includes symmetrical first and second angular corner block units for joining horizontally adjacent block units disposed to one another at an acute angle other than perpendicular, said first and second angular corner block units having opposing longitudinal block orientations, whereby said first and second angular corner block units allow adjacent block courses to traverse alternating longitudinal directions, thereby laterally offsetting vertical joints between adjacent block courses and improving layout configurability of said modular wall assembly.

13. The modular wall assembly system of claim 1, wherein said system of block units includes an adapter block unit having identical longitudinal block orientations, wherein longitudinally adjacent blocks having opposing longitudinal directions are joined, thereby improving layout configurability of said modular wall assembly.

14. The modular wall assembly system of claim 1, wherein said system of block units includes symmetrical first and second junction block units for joining horizontally adjacent block units disposed perpendicularly, said first and second junction block units having opposing longitudinal block orientations, whereby said first and second junction block units allow adjacent block courses to traverse alternating longitudinal directions, thereby laterally offsetting vertical joints between adjacent block courses and improving layout configurability of said modular wall assembly.

15. The modular wall assembly system of claim 1, wherein said system of block units includes a terminal block unit having a single longitudinal block orientation, wherein a longitudinally adjacent block course is joined and terminated, thereby improving layout configurability of said modular wall assembly.

16. The system of block units of claim 1, wherein said system of block units includes at least one block component face corresponding to a wall surface, said block component face being premolded with at least one vertical groove formed parallel to the center line of an encapsulated vertical passageway for receiving material, thereby providing means for designating a line of attachment to a structural component encapsulated in said vertical passageway.

17. The modular wall assembly system of claim 1, wherein said modular wall assembly system includes a system of modular block units wherein at least one of its courses has modular block units made from a material selected from the group consisting of cement, fiber-reinforced cement, wood, stone, ceramic, metal, gypsum, and plastic.

18. The modular wall assembly system of claim 1, wherein said modular wall assembly system includes a system of modular block units wherein at least one of its above grade courses has modular block units molded from a lightweight insulating material.

19. The modular wall assembly system of claim 1, wherein said modular wall assembly system includes a system of modular block units wherein at least one of its below grade courses has modular block units molded from a material having structural properties suitable for resisting lateral forces due to hydrostatic pressure.