MODULAR BLOCK STRUCTURES AND ASSEMBLIES THEREOF

Modular block structures and assemblies thereof for building wall facades comprise a plurality of interconnected preformed blocks with spacers allowing the user to position the modular block structures in even rows and columns. The modular block structures include panels with block forms on their front faces. The top and bottom edges of lower and upper panels in an assembly are complementarily configured to be mated. The lateral sides of adjacent panels of an assembly are complementarily configured to be mated. The modular block structures also include offset ends or lateral sides.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority on U.S. Provisional Patent Application Ser. No. 61/349,764 filed on May 28, 2010 and on U.S. Provisional Patent Application Ser. No. 61/416,962 filed on Nov. 24, 2010, both of which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present disclosure relates to blocks and modular blocks for building facades and building structures such as walls. The blocks include pre-cast, cement or concrete blocks and like articles. More specifically, but not exclusively the present disclosure relates modular block structures and assemblies thereof for being assembled in rows and columns on a wall structure thereby providing a wall façade.

BACKGROUND

Building wall structures using pre-cast blocks is well known. Many consumers appreciate the look of a wall including differently sized and shaped blocks. The foregoing gives a wall structure a more natural look, as if it was built by cut stones rather than pre-cast blocks.

Building such structures with pre-cast blocks is very costly and labor intensive since one would first have to provide various types of pre-cast blocks greatly increasing production time and costs. Furthermore, when assembling the blocks, given their varying dimension, the building process must be well thought out as to make sure the differently sized and configured blocks can actually be properly put together like a puzzle to provide for a uniform wall.

OBJECTS

It is an object of the present disclosure to provide a modular block structure.

It is an object of the present disclosure to provide a modular bloc assembly.

It is an object of the present disclosure to provide blocks with offset ends.

It is an object of the present disclosure to provide a modular block façade with offset ends.

It is an object of the present disclosure to provide a method of building a structure using blocks.

SUMMARY

In accordance with an aspect of the disclosure there is provided a modular block structure for building a wall façade when assembled on a wall structure in at least one row with similar modular block structures, the modular block structure comprising: a panel comprising a front face and a rear side and defining in one position thereof top and bottom edges and first and second lateral sides, the rear side providing for being mounted to the wall structure; and a plurality of blocks formed on the front face, wherein the first lateral side is complementarily shaped with the second lateral side of another similar modular block structure and wherein the second lateral side is complementarily shaped with the first lateral side of another similar modular block structure.

In accordance with an aspect of the disclosure, there is provided a modular block assembly for building a wall façade comprising: a plurality of modular block structures for being assembled in at least one row on a wall structure, each modular block structure comprising a panel comprising front face and a rear side and defining in one position thereof top and bottom edges and first and second lateral sides, the rear side providing for being mounted to the wall structure and a plurality of blocks formed on the front face, wherein the lateral sides of adjacently assembled modular block structures are complementarily configured so as to be mated.

In accordance with an aspect of the disclosure, there is provided a modular block structure for building a wall façade when assembled with similar modular block structures assembled in at least one columns on a wall structure, the modular block structure comprising: a panel comprising a front face and a rear side and defining in one position thereof top and bottom edges and first and second lateral sides, the rear side providing for being mounted to the wall structure; and a plurality of blocks formed on the front face, wherein the top and bottom edges comprises mating elements for the top edge of the modular block structure to mate with the bottom edge of an upper similar modular block structure and providing for the bottom end of the modular block structure to mate with the top end of a lower similar modular block structure.

In accordance with an aspect of the present disclosure, there is provided a modular block assembly for building a wall façade comprising: a plurality of modular block structures of being assembled in at least one columns on a wall structure, each modular block structure comprising a panel comprising a front face and a rear side and defining in one position thereof top and bottom edges and first and second lateral sides, the rear side providing for being mounted to the wall structure, and a plurality of blocks formed on the front face, wherein the top and bottom edges comprises mating elements for the top edge of the modular block structure to mate with the bottom edge of an upper similar modular block structure and providing for the bottom end of the modular block structure to mate with the top end of a lower similar modular block structure.

In an embodiment, the first lateral side comprises a first upper later side portion and a second lower lateral side portion interconnected by an auxiliary top edge providing an offset therebetween, the auxiliary top edge being interconnected the top edge by the first upper later side portion providing an offset therebetween, the second lateral side comprising a second upper lateral side portion and a second lower lateral side portion interconnected by an auxiliary bottom edge providing an offset therebetween, the auxiliary bottom edge being interconnected to the bottom edge by the second lower lateral side portion providing an offset therebetween.

In an embodiment, the top and bottom edges comprises mating elements providing for the top edge of the modular block structure to mate with the bottom end of an upper similar modular block structure and providing for the bottom end of the modular block structure to mate with the top end of a lower similar modular block structure when assembling the modular block structure with the similar modular block structure in a column on the wall structure. In an embodiment, the top and bottom mating elements comprise respective L-shaped structures. In an embodiment, one of the top and bottom mating elements comprises a protrusion and the other of the top and bottom mating elements comprises an indentation. In an embodiment, the top and bottom mating elements comprise respective indentations.

In an embodiment, the panel rear side comprises wall mounting elements.

In an embodiment, the plurality of blocks formed on the front face are spaced apart so as to allow mortar to be filled therebetween. In an embodiment, the panel front face comprises a space surrounding the plurality of blocks for being filled with mortar. In an embodiment, the plurality of blocks are differently configured from one another. In an embodiment, the blocks comprise embossments formed on the panel front face and covered by a sheet of material. In an embodiment, the sheet of material comprises cementitious material.

In an embodiment, the panel is made of deformable material. In an embodiment, the panel comprises urethane foam. In an embodiment, panel and the plurality of blocks are formed of the same material.

In accordance with an aspect of the disclosure, there is provided a modular block structure for building a wall façade when assembled with similar modular block structures on a wall structure, the modular block structure comprising: a panel comprising a front face, a rear side for being mounted to the wall structure, top and bottom edges and first and second lateral sides; a deformable structure on the front face, wherein the deformable structure provides for being cut so as to provide block formations with grooves defined between the block formations.

In accordance with an aspect of the disclosure, there is provided a modular block assembly for building a wall façade comprising: a plurality of modular block structures, each modular block structure comprising a panel comprising a front face, a rear side, top and bottom edges and first and second lateral sides and a deformable structure on the front face, wherein the deformable structure provides for being cut so as to provide block formations with grooves defined between the block formations.

In an embodiment, the first lateral side is complementarily shaped with the second lateral side of another similar modular block structure and wherein the second lateral side is complementarily shaped with the first lateral side of another similar modular block structure when assembling the modular block structure with the similar modular block structure in a row on the wall structure. In an embodiment, the first lateral side comprises a first upper later side portion and a second lower lateral side portion interconnected by an auxiliary top edge providing an offset therebetween, the auxiliary top edge being interconnected to the top edge by the first upper later side portion providing an offset therebetween, the second lateral side comprising a second upper lateral side portion and a second lower lateral side portion interconnected by an auxiliary bottom edge providing an offset therebetween, the auxiliary bottom edge being interconnected to the bottom edge by the second lower lateral side portion providing an offset therebetween.

In an embodiment, the top and bottom edges comprise mating elements providing for the top edge of the modular block structure to mate with the bottom end of an upper similar modular block structure and providing for the bottom end of the modular block structure to mate with the top end of a lower similar modular block structure when assembling the modular block structure with the similar modular block structures in a column on the wall structure.

In an embodiment, the deformable structure comprises urethane foam.

In accordance with an aspect of the disclosure, there is provided a modular block structure for building a wall façade when assembled with similar modular block structures on wall structure, the modular block structure comprising: a plurality of blocks; a backing for interconnecting the plurality of blocks; and peripheral spacers for providing a predetermined space between one modular block structure and a similar adjacent modular structure.

In accordance with an aspect of the disclosure, there is provided a modular block structure assembly building a wall façade comprising: a plurality of modular block structures, each modular block structure comprising a plurality of blocks; a backing for interconnecting the plurality of blocks; and peripheral spacers for providing a predetermined space between one modular block structure and a similar adjacent modular block structure.

In accordance with an aspect of the disclosure, there is provided a modular block structure for building a wall façade when assembled with similar modular block structures on a wall structure, the modular block structure comprising: a plurality of blocks, spacer elements for interconnecting the plurality of blocks; and peripheral spacers for providing a predetermined space between one modular block structure and a similar adjacent modular block structure.

In accordance with an aspect of the disclosure, there is provided a modular block structure assembly for building a wall façade comprising: a plurality of modular block structures, each modular block structure comprising a plurality of blocks with spacer elements for interconnecting the plurality of blocks and peripheral spacers, wherein when assembling the plurality of modular block structures on a wall structure, the peripheral spacers provide a predetermined space between two adjacent modular blocks.

In an embodiment, the peripheral spacers protrude from the plurality of blocks.

In an embodiment, the blocks are differently configured from one another.

In accordance with an aspect of the disclosure, there is provided a modular block structure comprising: a generally rectangular main body defining in one position thereof main top and bottom surfaces and main front and rear surfaces, at least one of the front and rear surfaces defining a modular façade surface, the modular façade surface comprising at least one elongate groove defining adjacent block forms; a first end comprising a first upper lateral side and a first lower lateral side interconnected by an auxiliary top surface providing an offset therebetween, the auxiliary top surface being interconnected to the main body top surface by the first upper later side providing an offset therebetween; and a second end comprising a second upper lateral side and a second lower lateral side interconnected by an auxiliary bottom surface providing an offset therebetween, the auxiliary bottom surface being interconnected to the main body bottom surface by the second lower later side providing an offset therebetween, wherein when assembling a plurality of the modular block structures, the grooves of the assembled modular block structure are adapted to be filled with mortar and the first end of one modular block structures is adapted to mate with the second end of another adjacent modular block structure.

In accordance with an aspect of the disclosure, there is provided a modular block structure assembly comprising: a plurality of modular block structures, each of modular block structure comprises a generally rectangular main body defining in one position thereof main top and bottom surfaces and main front and rear surfaces, at least one of the front and rear surfaces defining a modular façade surface, the modular façade surface comprising at least one elongate groove defining adjacent block forms; a first end comprising a first upper lateral side and a first lower lateral side interconnected by an auxiliary top surface providing an offset therebetween, the auxiliary top surface being interconnected to the main body top surface by the first upper later side providing an offset therebetween; and a second end comprising a second upper lateral side and a second lower lateral side interconnected by an auxiliary bottom surface providing an offset therebetween, the auxiliary bottom surface being interconnected to the main body bottom surface by the second lower later side providing an offset therebetween, wherein when assembling the plurality of modular block structures, the grooves of the assembled modular block structures are adapted to be filled with mortar and the first end of one modular block structure is adapted to mate with the second end of another adjacent modular block structure.

In embodiment, the modular façade comprises at least two block forms. In an embodiment, at least two block forms are differently configured.

In embodiment, each generally rectangular main body is similarly constructed.

In embodiment, each main body comprises a motif of the block forms. In embodiment, each main body comprises a similar motif.

In accordance with an aspect of the disclosure, there is provided a building block comprising: a generally rectangular main body defining in one position thereof main top and bottom surfaces and main front and rear surfaces; a first end comprising a first upper lateral side and a first lower lateral side interconnected by an auxiliary top surface providing an offset therebetween, the auxiliary top surface being interconnected to the main body top surface by the first upper later side providing an offset therebetween; and a second end comprising a second upper lateral side and a second lower lateral side interconnected by an auxiliary bottom surface providing an offset therebetween, the auxiliary bottom surface being interconnected to the main body bottom surface by the second lower later side providing an offset therebetween, wherein when interconnecting two like building blocks end to end, the first end of one building block mates with the second end of another adjacent building block.

In accordance with an aspect of the disclosure, there is provided a building block assembly comprising: a plurality of building blocks, each building block comprising: a generally rectangular main body defining in one position thereof main top and bottom surfaces and main front and rear surfaces; a first end comprising a first upper lateral side and a first lower lateral side interconnected by an auxiliary top surface providing an offset therebetween, the auxiliary top surface being interconnected to the main body top surface by the first upper later side providing an offset therebetween; and a second end comprising a second upper lateral side and a second lower lateral side interconnected by an auxiliary bottom surface providing an offset therebetween, the auxiliary bottom surface being interconnected to the main body bottom surface by the second lower later side providing an offset therebetween, wherein when interconnecting two like building blocks end to end, the first end of one building block mates with the second end of another adjacent building block.

Other objects, advantages and features of the present disclosure will become more apparent upon reading of the following non-restrictive description of illustrative embodiments thereof, given by way of example only with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

In the appended drawings, where like reference numerals indicate like elements throughout and where:

FIG. 1 is front elevational view of a modular block structure in accordance with a non-restrictive illustrative embodiment of the present disclosure;

FIG. 2 is a front view of an modular block assembly including a plurality of assembled modular block structures in accordance with a non-restrictive illustrative embodiment of the present disclosure;

FIG. 3 is front elevational view of a modular block structure in accordance with another non-restrictive illustrative embodiment of the present disclosure;

FIG. 4 is a front view of an modular block assembly including a plurality of assembled modular block structures in accordance with a non-restrictive illustrative embodiment of the present disclosure;

FIG. 5 is front perspective view of a modular block structure in accordance with a further non-restrictive illustrative embodiment of the present disclosure;

FIG. 6 is a lateral perspective view of the modular block structure of FIG. 5;

FIGS. 7a, 7b and 7c show lateral sectional view of interconnected upper and lower modular block structures in accordance with other non-restrictive illustrative embodiments of the present disclosure;

FIG. 8 is lateral section view of the top end of modular block structure with a wall connector in accordance with a non-restrictive illustrative embodiment of the present disclosure;

FIG. 9 is a sectional view of a modular block structure in accordance with yet another non-restrictive illustrative embodiment of the present disclosure;

FIG. 10 is a sectional view of a modular block structure in accordance with yet a further non-restrictive illustrative embodiment of the present disclosure;

FIG. 11 is a front perspective view of a modular block structure in accordance with still another non-restrictive illustrative embodiment of the present disclosure;

FIG. 12 is a rear view of the modular block structure of FIG. 11;

FIG. 13 is a perspective view of a pair of building blocks in accordance with a non-restrictive illustrative embodiment of the present disclosure being interconnected end to end;

FIG. 14 is a perspective view of a pair of modular blocks in accordance with a non-restrictive illustrative embodiment of the present disclosure being interconnected end to end;

FIGS. 15-22 are front elevational views of modular blocks in accordance with non-restrictive illustrative embodiments of the present disclosure; and

FIG. 23 is a front elevational view of the modular blocks of FIGS. 15-22 being assembled to provide a building structure such as a wall.

 DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Modular block structures and assemblies thereof for building wall facades comprise a plurality of interconnected preformed blocks with spacers allowing the user to position the modular block structures in even rows and columns. The modular block structures include panels with block forms on their front faces. The top and bottom edges of lower and upper panels in an assembly are complementarily configured to be mated. The lateral sides of adjacent panels of an assembly are complementarily configured to be mated.

A modular building block comprises a generally rectangular main body and first and second ends. The main body defines main top, bottom, front and rear surfaces. At least one, of the front and rear surfaces, defines a modular façade surface having grooves defining block forms. The first end comprises first upper and lower lateral sides interconnected by an auxiliary top surface providing an offset therebetween. The auxiliary top surface is interconnected to the main body top surface by the first upper later side providing an offset therebetween. The second end comprises second upper and lower lateral sides interconnected by an auxiliary bottom surface providing an offset therebetween. The auxiliary bottom surface is interconnected to the main body bottom surface by the second lower lateral side providing an offset therebetween. When assembling like blocks to build a structure, the grooves of the blocks are adapted to be filled with mortar and the first ends of the blocks are adapted to mate with the second ends of adjacent blocks.

With reference to the Figures non-limiting illustrative embodiments according to aspects of the disclosure will now be described.

FIG. 1 shows a modular block structure 10 comprising three pre-formed blocks 12 which are interconnected via spacers 14 in the form of short stems. The modular block structure 10 includes opposite offset ends 16 and 18 forming L-shaped openings at each side 16 and 18. As such, the end 16 of one modular structure 10 mates with the end 18 of an adjacent modular structure 10 thereby providing modular block structure assembly 20 such as that shown in FIG. 2 when building a wall façade.

The modular block structures 10 also include outer or peripheral spacers 22 in the form of tabs in order to assemble similar modular block structures at predetermined distances therebetween. The blocks 12 are provided with uneven perimeters 23 in order give the illusion of being cut from stone which are not suitable for acting as locators in order to properly and easily assemble structures 10 in vertical and horizontal side by side rows. The tabs 22 provide the structures 10 with being evenly assembled which building a wall façade.

In order to provide a more natural looking wall façade, each modular block structure can include at least three blocks 12A, 12B, 12C (see FIG. 2) having different lengths and motifs. The random layout of blocks on a wall can further be provided by using several different types of modular block structures rather than a single type of structure having the same block motif. The foregoing is shown in FIG. 2 for example, where the assembly 20 includes three similar modular block structures 10 and an additional modular block structure 11 having a different configuration.

Once assembled on a wall, the various blocks 12 form spaces or valleys therebetween which are filled by mortar thereby completing the wall façade.

FIG. 3 shows a modular block structure 30 comprising three blocks 12 which are held together by a backing 32. In essence, the modular structure 30 is similar to structure 10 except that instead of spacers 14, it is provided with a backing panel 32. As such, the modular structure also includes spacer tabs 22.

FIG. 4 shows assembled modular block structures 30 as well as additional modular structure 31 providing a modular block assembly 36 for building a wall façade. As explained in FIG. 2, the blocks 12 are spaced from each other and these spaces are filled with mortar in order to complete the wall façade providing it with a plurality of different and randomly positioned uneven blocks giving the allure of a wall made by naturally cut stone.

Turning to FIGS. 5 and 6, a modular block or stone structure 40 is shown comprising panel 42 having offset top and bottom portions 41 and 43, respectively, and thereby defining a pair of offset ends 44 and 46. The ends 44 and 46 provide L-shaped openings 48 and 50 for mating with similar modular structures 40. In essence, the end 46 of one modular structure 40 will mate with the end 44 of an adjacent modular structure 40.

The front face 52 of the panel 42 includes a plurality of block or stone structures 13 which can be provided in a variety of random formations. The spaces or valleys 54 between the stone structures 13 can be filled with mortar as previously explained.

FIGS. 9 and 10 show respective sectional views of the modular block structure 40. As shown, the complete structure 40 can be made out of the same material and comprise a formation on its front face 52 in order to provide stone façades 13 as shown by embossments 56. The embossments 56 can be covered by a sheet 58 made of cementitious material, such as concrete material for example, giving the allure of a stone as shown in FIG. 10.

The panel 42, itself, can be made from urethane foam or other suitable and light material. In this way, the module 40 is itself is provided is light and easy to handle and assemble.

With respect to FIG. 9, longitudinal elements 60 can be inserted on the rear side 62 of the modular structure 40, these longitudinal elements 60 can then be include hooks or other mounting members including adhesive material for being mounted to a wall surface. In another embodiment, the longitudinal elements 60 can be used during processing of the structures 40 to be removed so as to provide a rear opening similar to the one discussed in FIG. 8 below.

FIGS. 7a to 7c show three respective pair 64, 66 and 68 of top and bottom modular structures interconnected at their respective bottom and top ends

FIG. 7a shows a pair 64 of top and bottom modular structures 70 and 72 respectively. The bottom end 74 of the top modular structure 70 is interconnected to the top end 76 of the bottom structure 72. Ends 74 and 76 define mutually complementary L-shaped structures that are easy to mate during assembly.

FIG. 7b shows a pair 66 of top and bottom modular structures 78 and 80 respectively. The bottom end 82 of the top modular structure 78 is interconnected to the top end 84 of the bottom structure 80. The top end 84 of the bottom structure 80 includes a protrusion 86 for being received by a complementary indentation 88 formed at the bottom end 82 of the top modular structure 78.

FIG. 7c shows a pair 68 of top and bottom modular structures 90 and 92 respectively. The bottom end 94 of the top modular structure 90 is interconnected to the top end 96 of the bottom structure 94. The ends 94 and 96 include respective interfacing indentations 98 for creating a latitudinal bore to receive a connector element 100 therein.

FIG. 8 shows the top end 102 of a modular structure 104 having an L-shaped top formation 106 for mating with a complimentarily shaped bottom end of an upper modular structure (not shown). The inner or rear side 108 of this structure 104 includes an opening 110 for receiving the hook end 112 of an L-shaped connector 114 which is anchored into a wall via a fastener 116.

Therefore, the modular structures of the disclosure can be assembled in horizontal and vertical rows, the side tabs or the edges of the panel provide for positioning adjacent panels in horizontal rows, the top and bottom ends provide for mating upper and lower panels together thereby hiding wall connectors such as 114 behind the assembles panels. The top ends of the uppermost panels are covered by a longitudinal covering which hides jagged top ends and which can itself be maked by mortar. The spaces between stone or block formations are filled with mortar thereby completing the wall façade.

The backing panels provided herein can also provide insulation depending on the material they are made from.

FIGS. 11 and 12 show a modular structure 120 having an offset backboard or panel 122 with an offset façade structure 124 on its front face 126. The façade structure 124 can be provided in foam or other suitable material in order to be randomly cut or cut according to a pre-defined motif by the user thereby forming block or stone formations on the front face 126 of the backboard 122. When a plurality of such modular structures 120 are assembled together as previously described, then the spaces between the various stones or blocks can be filled with mortar. The block or stone forms can also be covered by a thin sheet of concrete in order to give them a more natural allure.

As shown in FIG. 12, the rear side 128 comprises a plurality of mounting elements 130 such as apertures for mounting this modular structure 120 to a wall.

FIG. 13 shows a pair of similar building blocks 1010A and 1010B. Each building block 10A or 10B includes a respective generally rectangular main body 12 having first and second offset ends 14 and 16 respectively.

The main body 1012 includes top and bottom surfaces 1018 and 1020 respectively as well as front and rear surfaces 1022 and 1024 respectively. Of course, a surface is defined to be top or bottom and front or rear depending on how a block 1010A or 1010B is positioned.

The first end 1014 includes a first upper lateral side 1026 and a first lower lateral side 1028. Lateral sides 1026 and 1028 are offset in that the upper later side 1026 is positioned inwardly relative to the lower lateral side 1028. The lateral sides 1026 and 1028 are interconnected by an auxiliary top surface 1030 providing the offset therebetween. The auxiliary top surface 1030 is interconnected to the main body top surface 1018 by the first upper later side 1026 providing an offset therebetween. The auxiliary top surface 1030 is interconnected to bottom surface 1020 via the lower lateral side 1028.

The second end 1016 includes a second upper lateral side 1032 and a second lower lateral side 1034. Lateral sides 1032 and 1034 are offset in that the upper later side 1032 is positioned outwardly relative to the lower lateral side 1034. The lateral sides 1032 and 1034 are interconnected by an auxiliary bottom surface 1036 providing the offset therebetween. The auxiliary bottom surface 1036 is interconnected to the main body bottom surface 1020 by the second lower later side 1034 providing an offset therebetween. The auxiliary bottom surface 1036 is interconnected to bottom surface 1020 via the lower lateral side 1034.

In this way, each block 1010A and 1010B includes upper and lower offset body portions 1011 and 1013 respectively (see FIG. 14). Upper body portion 1011 is defined between lateral sides 1026 and 1032 and lower body portion 1013 is defined between lateral sides 1028 and 1034. With respect to FIG. 15, the upper and lower body portions can be differently sized, in this example, the upper portion 1011 is larger than the lower portion 1013.

The blocks 1010A and 1010B can be positioned end to end, with the first end 1014 of one of blocks 1010A or 1010B mating with the second end 16 of the other of blocks 1010A or 1010B.

As shown in FIG. 13, the auxiliary top surface 1030 of the first end 1014 of a block 1010B received thereon the auxiliary bottom surface 1036 of the second end 1016 of the adjacent block 1010A. In this example, the rear surface 1024 of block 1010A is abutting the first lateral side 1026 of block 1010B thereby providing a right angle between the blocks 1010A and 1010B for building corners.

In another example, when the blocks are adjoined end to end, the bottom surface 1036 of the block 1010A is supported by the top surface 36 of the block 1010B with the lateral side 1032 of block 1010A abutting the lateral side 1026 of block 1010B and thereby forming a wail structure therewith.

FIG. 14 shows a pair of blocks 1010C and 1010D which are similar in construction with previously described blocks 10A and 10B except that the former include grooves 1038 which define block façade forms 1040. The grooves 1038 can be vertical 1038V (see FIG. 16) or horizontal 1038H (see FIG. 16) and be defined on any surface of the blocks described herein such as the front and rear surfaces 1022 and 1024 and the lateral sides 1026, 1028, 1032 and 1034 thereby defining a façade surface which provide block forms 1040.

FIGS. 15-22 respectively show blocks 1010E, 1010F, 1010G, 1010H, 1010I, 1010J, 1010K and 1010L which are all similarly constructed with varying groove motifs 1042 (see FIGS. 17 and 18) which define different types of blocks forms 1040. In this way each block provides a block form layout or motif 1044 (see FIG. 19). The layout or motif of a given block façade surface includes differently sized block forms, some being larger while other longer. Of course, the skilled artisan can easily design different layouts of motifs 1044 of block forms 1040 depending on where the grooves 1038 will be made.

The blocks 1010E, 1010F, 1010G, 1010H, 1010I, 1010J, 1010K and 1010L are shown to have similar configurations but they may include similar or different sizes. For example, the blocks 1010E, 1010F and 1010K have a similar groove and block form motifs 1042/1044 with the block 1010G, 1010H and 1010L respectively but not the same size.

FIG. 23 shows that when stacking the blocks described herein and connecting them end to end in order to build a wall structure W, the various groove motifs 1042 and block form motifs 1044 defined by the blocks forms 1040 and grooves 1038 provide a wall façade 1046. This wall façade 1046 is further defined when filling the grooves 1038 with mortar giving the impression that each block form 1040 is in fact an independent pre-cast connected to other precast blocks.

In this way, the blocks 1010E, 1010F, 1010G, 1010H, 1010I, 1010J, 1010K and 1010L act as modular building blocks providing with only a limited number of groove and block form motifs 1042/1044 provides a large variety of wall facades 46 since it avoids repeating a given block form layout.

The foregoing provides for building a plurality of pre-cast blocks having the same shape and size, thereby making production relatively cheaper and easier than building differently sized and configured building blocks. The offset ends of the blocks allow for mating the blocks end to end when creating a horizontal row, their similar lengths allows for creating columns by stacking one row above the next. Providing different groove and block form motifs on the façade surfaces of the blocks and randomly placing the pre-cast blocks avoids repeating blocks layout patterns and greatly increases the chances of producing a wall structure that gives the impression of having been build with separate differently shaped and sized blocks (i.e. the block forms) and without redundancy in the sequence of block layout.

It is to be understood that the disclosure is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The disclosure is capable of other embodiments and of being practiced in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation.

Hence, although the present disclosure has been described hereinabove by way of embodiments thereof, it can be modified, without departing from the spirit, scope and nature of the subject disclosure as defined herein.

Claims

1. A modular block structure for building a wall façade when assembled on a wall structure in at least one row with similar modular block structures, said modular block structure comprising:

a panel comprising a front face and a rear side and defining in one position thereof top and bottom edges and first and second lateral sides, said rear side providing for being mounted to the wall structure; and
a plurality of blocks formed on said front face,
wherein said first lateral side is complementarily shaped with the second lateral side of another similar modular block structure and wherein said second lateral side is complementarily shaped with the first lateral side of another similar modular block structure.

2. A modular block structure according to claim 1, wherein said first lateral side comprises a first upper later side portion and a second lower lateral side portion interconnected by an auxiliary top edge providing an offset therebetween, said auxiliary top edge being interconnected said top edge by said first upper later side portion providing an offset therebetween, said second lateral side comprising a second upper lateral side portion and a second lower lateral side portion interconnected by an auxiliary bottom edge providing an offset therebetween, said auxiliary bottom edge being interconnected to said bottom edge by said second lower lateral side portion providing an offset therebetween.

3. A modular block structure according to claim 1, wherein said top and bottom edges comprises mating elements providing for said top edge of said modular block structure to mate with the bottom end of an upper similar modular block structure and providing for said bottom end of said modular block structure to mate with the top end of a lower similar modular block structure when assembling said modular block structure with the similar modular block structure in a column on the wall structure.

4. A modular block structure according to claim 3, wherein said top and bottom mating elements comprise respective L-shaped structures.

5. A modular block structure according to claim 3, wherein one of said top and bottom mating elements comprises a protrusion and the other of said top and bottom mating elements comprises an indentation.

6. A modular block structure according to claim 3, wherein said top and bottom mating elements comprise respective indentations.

7. A modular block structure according to claim 1, wherein said panel rear side comprises wall mounting elements.

8. A modular block structure according to any one of claims claim 1, wherein said a plurality of blocks formed on said front face are spaced apart so as to allow mortar to be filled therebetween.

9. A modular block structure according to claim 1, wherein said panel front face comprises a space surrounding said plurality of blocks for being filled with mortar.

10. A modular block structure according to claim 1, wherein said plurality of blocks are differently configured from one another.

11. A modular block stricture according to claim 1, wherein said panel is made of deformable material.

12. A modular block stricture according to claim 1, wherein said panel comprises urethane foam.

13. A modular block structure according to claim 1, wherein said panel and said plurality of blocks are formed of the same material.

14. A modular block structure according to claim 1, wherein said blocks comprise embossments formed on said panel front face and covered by a sheet of material.

15. A modular block structure according to claim 14, wherein said sheet of material comprises cementitious material.

16. (canceled)

17. A modular block assembly for building a wall façade comprising:

a plurality of modular block structures for being assembled in at least one row on a wall structure, each said modular block structure comprising a panel comprising front face and a rear side and defining in one position thereof top and bottom edges and first and second lateral sides, said rear side providing for being mounted to the wall structure and a plurality of blocks formed on said front face,
wherein said lateral sides of adjacently assembled modular block structures are complementarily configured so as to be mated.

18. A modular block structure for building a wall façade when assembled with similar modular block structures assembled in at least one columns on a wall structure, said modular block structure comprising:

a panel comprising a front face and a rear side and defining in one position thereof top and bottom edges and first and second lateral sides, said rear side providing for being mounted to the wall structure; and
a plurality of blocks formed on said front face,
wherein said top and bottom edges comprises mating elements for said top edge of said modular block structure to mate with the bottom edge of an upper similar modular block structure and providing for said bottom end of said modular block structure to mate with the top end of a lower similar modular block structure.

19. A modular block structure according to claim 18, wherein said top and bottom mating elements comprise respective L-shaped structures.

20. A modular block structure according to claim 18, wherein one of said top and bottom mating elements comprises a protrusion and the other of said top and bottom mating elements comprises an indentation.

21. A modular block structure according to claim 18, wherein said top and bottom mating elements comprise respective indentations.

22. A modular block structure according to claim 18, wherein said first lateral side is complementarily shaped with the second lateral side of another similar modular block structure and wherein said second lateral side is complementarily shaped with the first lateral side of another similar modular block structure when assembling said modular block structure with the similar modular block structure in a row on the wall structure.

23. A modular block structure according to claim 22, wherein said first lateral side comprises a first upper later side portion and a second lower lateral side portion interconnected by an auxiliary top edge providing an offset therebetween, said auxiliary top edge being interconnected to said top edge by said first upper later side portion providing an offset therebetween, said second lateral side comprising a second upper lateral side portion and a second lower lateral side portion interconnected by an auxiliary bottom edge providing an offset therebetween, said auxiliary bottom edge being interconnected to said bottom edge by said second lower lateral side portion providing an offset therebetween.

24. (canceled)

25. A modular block structure according to claim 18, wherein said a plurality of blocks formed on said front face are spaced apart so as to allow mortar to be filled therebetween.

26. A modular block structure according to claim 18, wherein said panel front face comprises a space surrounding said plurality of blocks for being filled with mortar.

27. (canceled)

28. A modular block structure according to claim 18, wherein said panel is made of deformable material.

29. A modular block stricture according to claim 28, wherein said panel comprises urethane foam.

30. (canceled)

31. A modular block structure according to claim 18, wherein said blocks comprise embossments formed on said panel front face and covered by a sheet of material.

32. A modular block structure according to claim 31, wherein said sheet of material comprises cementitious material.

33. (canceled)

34. A modular block assembly for building a wall façade comprising:

a plurality of modular block structures of being assembled in at least one columns on a wall structure, each said modular block structure comprising a panel comprising a front face and a rear side and defining in one position thereof top and bottom edges and first and second lateral sides, said rear side providing for being mounted to the wall structure, and a plurality of blocks formed on said front face,
wherein said top and bottom edges comprises mating elements for said top edge of said modular block structure to mate with the bottom edge of an upper similar modular block structure and providing for said bottom end of said modular block structure to mate with the top end of a lower similar modular block structure.

35. A modular block structure for building a wall façade when assembled with similar modular block structures on a wall structure, said modular block structure comprising:

a panel comprising a front face, a rear side for being mounted to the wall structure, top and bottom edges and first and second lateral sides;
a deformable structure on said front face,
wherein said deformable structure provides for being cut so as to provide block formations with grooves defined between said block formations.

36-40. (canceled)

41. A modular block assembly for building a wall façade comprising:

a plurality of modular block structures, each said modular block structure comprising a panel comprising a front face, a rear side, top and bottom edges and first and second lateral sides and a deformable structure on said front face,
wherein said deformable structure provides for being cut so as to provide block formations with grooves defined between said block formations.

42. A modular block structure for building a wall façade when assembled with similar modular block structures on wall structure, the modular block structure comprising:

a plurality of blocks;
a backing for interconnecting said plurality of blocks; and
peripheral spacers for providing a predetermined space between one modular block structure and a similar adjacent modular structure.

43-61. (canceled)

Patent History
Publication number: 20110289877
Type: Application
Filed: May 31, 2011
Publication Date: Dec 1, 2011
Inventor: Horacio CORREIA (Terrebonne)
Application Number: 13/149,189
Classifications
Current U.S. Class: Foam (52/309.4); Laterally Related Modules; E.g., Back-to-back (52/424); Laterally Related, Individually Assembled Courses (52/561)
International Classification: E04B 1/04 (20060101); E04C 2/20 (20060101); E04B 1/02 (20060101); E04B 2/02 (20060101);