INTERLOCKING MASONRY SYSTEM

A structural masonry element includes an element body having a perimeter wall defined by height, and having parallel top and bottom surfaces, each of the top and bottom surfaces having an external lunate shape. The external lunate shape is defined by a material section resulting from a symmetrical lens cut away from a first circle. The symmetrical lens is a result of an intersection of the first circle with a second circle. Radii of the first and second circles are equivalent. A distance between centers of the first circle and second circle is greater than each of the first and second radii. The external lunate shape is configured to nest an analogous interfacing masonry element within the symmetrical lens and thereby provide a spherical first interlocking masonry joint. A mortarless masonry structure including a plurality of such masonry elements is also considered.

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Description

The present disclosure relates to a masonry system using interlocking structural elements.

In the civil engineering context, construction includes the processes involved in generating assets, such as buildings, infrastructure, industrial facilities, and associated activities through to the end of the structure's life. Such construction typically starts with planning, financing, and design, and continues until the asset is built and ready for use. Construction generally also covers repairs and maintenance work, work to expand, extend, and improve the structural asset, and the eventual demolition, dismantling, or decommissioning of the structure.

In civil engineering, masonry is commonly used for construction of walls and buildings. Masonry uses structural elements, such as concrete blocks, bricks, or stone. Such structural elements are generally produced in bulk quantities and may be found in various materials and sizes. Masonry structural elements are typically joined using mortar, adhesives, or through interlocking. Individual masonry elements are typically strongest in compression. To enhance integrity of the finished asset, sections of a masonry structure may be reinforced with high tensile strength elements, such as rebar.

SUMMARY

A structural masonry element or block includes an element body having a perimeter or side wall defined by height and parallel top and bottom surfaces. Each of the top and bottom surfaces has an external lunate, i.e., semilunar or crescent, shape in respective top and bottom views. The external lunate shape is defined by a material section resulting from a symmetrical lens cut away from a first circle having a first radius. The symmetrical lens is a result of an intersection of the first circle with a second circle having a second radius equivalent to the first radius. A distance between a center of the first circle and a center of the second circle is greater than each of the first and second radii. The external lunate shape is configured to nest an analogous interfacing masonry element within the symmetrical lens and thereby provide a spherical first interlocking masonry joint.

Each of the top and bottom surfaces may additionally have an internal lunate shape, thereby defining a hollow section arranged concentrically with and oriented same as the external lunate shape. In such an embodiment, the internal lunate shape may be configured to accept a reinforcement material, such as a composite or concrete, therein.

The top surface may define a groove configured to accept a horizontal first rebar element or a first tensioning cable extending across each of the external and internal lunate shapes.

The bottom surface may define a groove configured to accept a horizontal second rebar element or a second tensioning cable extending across each of the external and internal lunate shapes.

The element body may additionally define a fillet relief in a corner of the internal lunate shape configured to accept a vertical third rebar element or a third tensioning cable extending along, e.g., parallel to, the perimeter wall.

The element body may include a longitudinal axis and the perimeter wall may be arranged along the longitudinal axis. The perimeter wall may include an outer section having a first slanted surface defining a generally conoid shape for water shedding. The first slanted surface may have a generally concave profile. The generally concave profile of the first slanted surface may be defined by a constant radius.

Alternatively, the generally concave first slanted surface may have a compound-angle profile. In such an embodiment, the first slanted surface may include a first slanted surface section arranged at a first angle relative the longitudinal axis, a second slanted surface section arranged at a second angle relative the longitudinal axis, and a third slanted surface section arranged at a third angle relative the longitudinal axis. The third angle may be greater than the second angle and the second angle may be greater than the first angle.

The bottom surface may be inset relative to the perimeter wall toward the top surface. In such an embodiment, the element body may include an inner section having a second slanted surface, e.g., an inclined transition defining a generally conoid shape, between the perimeter wall and the inset bottom surface. The second slanted surface may be configured to interface with and nest a compound-angle first slanted surface of an analogous second interfacing masonry element, when the analogous second interfacing masonry element is arranged against the bottom surface to nest therein and thereby provide a conoid or tapered second interlocking masonry joint.

The element body may be formed from high-density pressed concrete formed under a 12-14 MPa load.

Each of the first and second radii may be 4.00 inches, and the distance between the center of the first circle and the center of the second circle may be 5.65 inches.

A mortarless masonry structure including a plurality of such masonry elements and other nesting masonry blocks is also disclosed.

The mortarless masonry structure may include a horizontal first rebar element or a first tensioning cable. In such an embodiment, the top surface may define a groove configured to accept the horizontal first rebar element or the first tensioning cable extending across each of the external and internal lunate shapes.

The mortarless masonry structure may also include a horizontal second rebar element or a second tensioning cable. In such an embodiment, the bottom surface may define a groove configured to accept a horizontal second rebar element or a second tensioning cable extending across each of the external and internal lunate shapes.

The mortarless masonry structure may additionally include a plurality of masonry finishing blocks, each configured to be mounted to and cover the hollow section in one of the plurality of masonry elements.

The mortarless masonry structure may also include a plurality of base masonry blocks configured to be mounted to a structural foundation and interface with at least some of the plurality of masonry elements. In such an embodiment, each base block may include top and bottom surfaces, each of the top and bottom surfaces of the base masonry blocks having an external lunate shape. Also, the external lunate shape of the masonry base block may be configured to interface with and nest an interfacing masonry base block to thereby generate a base masonry layer. In the subject embodiment, the top surface of each masonry base block may be configured to interface with and nest within the bottom surface of one of the plurality of masonry elements. Furthermore, the bottom surface of each masonry base block may be configured to interface with the structural foundation.

Each masonry base block may additionally define a first aperture extending perpendicular to each of the top and bottom surfaces. The first aperture may be configured to accept a fastener to thereby attach the masonry base block to the structural foundation.

The mortarless masonry structure may additionally include a vertical third rebar element or a third tensioning cable. In such an embodiment, each masonry base block may also define a second aperture extending perpendicular to each of the top and bottom surfaces. The second aperture may be configured to accept the vertical third rebar element or the third tensioning cable extending through at least one of the plurality of masonry elements located above the masonry base block and thereby strengthen the masonry structure.

The mortarless masonry structure may additionally include an adhesive applied in at least one of the first and second interlocking masonry joints and between the bottom surface of each masonry base block and the structural foundation.

At least a section of the masonry structure may be configured as a curved wall layout arranged in a horizontal plane.

At least a section of the masonry structure may include a masonry direction-changing block having a bidirectional external lunate shape.

At least a section of the masonry structure may be configured as an arc arranged in a vertical plane. In such an embodiment, the arc may include the masonry direction-changing block.

At least a section of the masonry structure may include one or more corner blocks, each having a fully (360-degree) cylindrical shape intended to interface with at least one of the masonry elements. The cylindrical shape of the corner blocks may thereby be configured to provide nesting transitions at various angles between adjacent or intersecting walls.

The above features and advantages, and other features and advantages of the present disclosure, will be readily apparent from the following detailed description of the embodiment(s) and best mode(s) for carrying out the described disclosure when taken in connection with the accompanying drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically illustrates a perspective view of an embodiment of a structural masonry element having an external lunate shape facilitating a first interlocking masonry joint in a mortarless masonry structure, according to the disclosure.

FIG. 1A schematically illustrates a perspective view of an alternative embodiment of the structural masonry element, according to the disclosure.

FIG. 2 schematically illustrates a side view of the structural masonry element shown in each of FIGS. 1 and 1A, according to the disclosure.

FIG. 3 schematically illustrates a top view of the embodiment of the structural masonry element shown in FIG. 1, according to the disclosure.

FIG. 3A schematically illustrates a top view of the embodiment of the structural masonry element shown in FIG. 1A, according to the disclosure.

FIG. 4 schematically illustrates a diagrammatic top view of geometric construction of the structural masonry element embodiments shown in FIGS. 1 and 1A, according to the disclosure.

FIG. 5 schematically illustrates a top view of a mortarless masonry structure including a plurality of masonry elements shown in FIGS. 1 and 1A, according to one embodiment of the disclosure.

FIG. 6 schematically illustrates a bottom perspective view of the embodiment of the structural masonry element shown in FIG. 1A, illustrating a blind hole marked on the perimeter wall of the masonry element for removal of material to accommodate a rebar or a tensioning cable, according to the disclosure.

FIG. 7 schematically illustrates a top view of the mortarless masonry structure having a curved wall profile generated by nested masonry elements shown in FIGS. 1 and 1A, according to the disclosure.

FIG. 8 schematically illustrates a bottom view of the embodiment of the structural masonry element shown in FIG. 1 with a rebar element situated in a specifically formed groove, according to the disclosure.

FIG. 8A schematically illustrates a bottom view of the embodiment of the structural masonry element shown in FIG. 1A with a rebar element situated in a specifically formed groove, according to the disclosure.

FIG. 9 schematically illustrates a side view of the embodiment of the structural masonry element shown in FIG. 1, depicting first and second slanted surfaces facilitating a tapered second interlocking masonry joint, according to the disclosure.

FIG. 9A schematically illustrates a side view of the embodiment of the structural masonry element shown in FIG. 1A, depicting another embodiment of the first slanted surface facilitating a tapered second interlocking masonry joint, according to the disclosure.

FIG. 10 schematically illustrates vertically stacked structural masonry elements shown FIG. 1 with horizontally and vertically positioned rebar elements extending therebetween, according to the disclosure.

FIG. 11 schematically illustrates vertically stacked structural masonry elements shown FIG. 1 and horizontally nested foundation blocks connected via rebar elements, such as shown in FIG. 10, and a tensioning cable extended therebetween, according to the disclosure.

FIG. 11A schematically illustrates a plurality of interfaced structural masonry elements shown FIG. 1A and other nesting masonry blocks connected via a tensioning cable having an anchor and guided by captured washers relative to the masonry elements, according to the disclosure.

FIG. 12 schematically illustrates a perspective view of a stack of direction-changing blocks, according to the disclosure.

FIG. 13 schematically illustrates a top view of an embodiment of the mortarless masonry structure using the direction-changing block shown in FIG. 12.

FIG. 14 schematically illustrates a perspective view of a stack of corner blocks with vertically positioned rebar elements extending therebetween, according to the disclosure.

FIG. 15 schematically illustrates a perspective view of an embodiment of the mortarless masonry structure, including the structural masonry elements, direction-changing blocks, corner blocks, and individual embodiments of multi-section blocks having two and three subsections, according to the disclosure.

FIG. 16 schematically illustrates a top view of a base block embodiment of the multi-section block having two subsections as shown in FIG. 15, according to the disclosure.

FIG. 17 schematically illustrates a bottom view of an interfacing block embodiment for engaging the multi-section block shown in FIG. 16.

FIG. 18 schematically illustrates a top view of a base block embodiment of the multi-section block having three subsections as shown in FIG. 15, according to the disclosure.

FIG. 19 schematically illustrates a bottom view of an interfacing block embodiment for engaging the multi-section block shown in FIG. 18.

FIG. 20 schematically illustrates a vertically oriented arc including the masonry direction-changing block. shown in FIG. 12, according to the disclosure.

 DETAILED DESCRIPTION

Those having ordinary skill in the art will recognize that terms such as “above”, “below”, “upward”, “downward”, “top”, “bottom”, “left”, “right”, etc., are used descriptively for the figures, and do not represent limitations on the scope of the disclosure, as defined by the appended claims. Referring to the drawings, wherein like reference numbers refer to like components, FIGS. 1-8, 10-12, and 14-15 show various views and embodiments of a structural masonry element 10 arranged in a three-dimensional X-Y-Z coordinate space, according to the present disclosure. The masonry element 10 is a principal building block for generating interconnecting structures, such as walls and columns, as will be described in the present disclosure.

As shown in FIG. 5, the structural masonry element 10 is adapted for generating a mortarless masonry structure 100, such as a retaining wall, a building, etc., to be discussed in detail below. Furthermore, the structural masonry element 10 is intended to generate such a mortarless masonry structure 100 via interfacing with other components, including but not limited to one or more analogous masonry elements 20, which are general duplicates of the masonry element 10. Such neighboring analogous masonry elements 20 may engage the masonry element 10 from above, below, and/or lateral sides, to construct, among other sections, load-bearing walls and columns. The constituent elements of the mortarless masonry structure 100 are configured, i.e., geometrically and structurally adapted, to interlock with one another using a “Roundbond Clutchlock” principle, to be discussed below. The masonry element 10 is thereby configured as the main building block for generating chains of walls and columns in structures employing the “Roundbond Clutchlock” principle.

With reference to FIG. 1, the structural masonry element 10 includes an element body 12 defined by a generally cylindrical form. The element body 12 has a substantially vertical perimeter wall 14-1 defined by a height H in a side view shown in FIG. 2 (generally representing each of the embodiments of the masonry element shown in FIGS. 1 and 1A) and having parallel top 14-2 and bottom 14-3 surfaces. The element body 12 includes, i.e., is arranged along, a longitudinal axis Z, defined as the element axis extending in a generally vertical direction. The element body 12 may be provided from high-density pressed concrete formed between tooling dies under a 12-14 MPa load generated by a suitable forming press. The perimeter wall 14-1 is arranged along the longitudinal axis Z. Each of the top and bottom surfaces 14-2, 14-3 has an external lunate, i.e., semilunar or crescent, shape 16 in respective top and bottom views shown in corresponding FIGS. 3 and 4. The external lunate shape 16 of each respective the top and bottom surface 14-2, 14-3 is defined or formed by a material section which results from (or remains after) a symmetrical lens 18 (shown in FIG. 3) is cut away from a first circle C1having a first radius R1 (shown in FIG. 4) and its center at the longitudinal axis Z. In other words, the external lunate shape 16 may be visualized as the remaining part of the first circle C1 after the symmetrical lens 18 is removed therefrom.

Generally, in two-dimensional geometry, a lens is a convex region bounded by two circular arcs joined to each other at their endpoints. For the lens shape to be convex, both arcs must bow outwards (convex-convex). Such a lens shape may be formed as an intersection of two circular disks. The subject lens shape may also be formed as a union of two circular segments (regions between the chord of a circle and the circle itself), joined along a common chord. Specifically, the symmetrical lens 18 defining the external lunate shape 16 of the structural masonry element 10 is a result of a geometric intersection of the first circle C1 with a second circle C2 having a second radius R2 equivalent to the first radius R1.

With resumed reference to FIG. 1, the external lunate shape 16 is in part generated by a distance D1 between a center of the first circle C1 and a center of the second circle C2 being greater than each of the first and second radii R1, R 2. As shown at least in FIGS. 5 and 7, the external lunate shape 16 is configured to nest the analogous interfacing masonry element 20 within the symmetrical lens 18 and thereby provide a spherical first interlocking masonry joint J1 of the mortarless masonry structure 100. The distance D1 thereby defines a width of the symmetrical lens 18 and a nesting interface area, i.e., the symmetrical lens 18, for adjacent/interlocking masonry elements, such as the masonry element 20.

In a particular embodiment, the structural masonry element 10 may have an effective overall outer diameter of 8.00 inches, an effective inside diameter of 4.50 inches, and a resultant wall thickness of 1.75 inches. The resultant first and second radii R1, R2of the respective first and second circles C1, C2 may be 4.00 inches, while the distance D1 between the center of the first circle and the center of the second circle may be 5.65 inches. Depending on a particular embodiment of the element body 12, the element body may have a height H of 6.00 inches. For manufacturability and tooling die longevity, transitions between intersecting surfaces defining the element body 12 may be finished with corner radii having a dimension in a range of 0.10-0.20 inches.

When viewed from the top, as shown in FIG. 4, during construction of the mortarless masonry structure 100, the subject adjacent masonry elements, e.g., elements 10 and 20, may be rotated with respect to each other via the spherical first interlocking masonry joint J1. Specifically, the spherical first interlocking masonry joint J1 permits the symmetrical lens 18 of the masonry element 20 to be positioned at a selected interface angle θi (shown in FIGS. 5 and 7) relative to the symmetrical lens 18 of the masonry element 10. Accordingly, the adjacent masonry elements 10 and 20 may be interlocked in various desired positions. As a result, the spherical first interlocking masonry joint J1 located between each pair of adjacent masonry elements permits the mortarless masonry structure 100 to have smooth curves and a flowing profile depicted in FIG. 7 and facilitates architecturally interesting and aesthetically pleasing designs.

With reference to FIGS. 3, 3A, 8, and 8A, each of the corresponding top and bottom surfaces 14-2, 14-3 may have an internal lunate shape 22, thereby defining a hollow section 24 within the element body 12. The hollow section 24 is arranged concentrically with and oriented same as, i.e., generally identically with, the external lunate shape 16. The internal lunate shape 22 shown in FIGS. 8 and 8A may be configured to accept a reinforcement material 26, such as a composite (such as compacted crushed granite mixed with water) or concrete filler, therein. With resumed reference to FIGS. 1, 1A, 3, and 3A, the top surface 14-2 may define groove(s) or chamber(s) 28 extending across and over the perimeter wall 14-1. Each groove 28 is configured to accept a horizontal first rebar element 30A or a first tensioning cable 30B (shown in FIGS. 3 and 3A) extending across each of the external and internal lunate shapes 16, 22. Additionally, the bottom surface 14-3 may define groove(s) or chamber(s) 32 (shown in FIGS. 8 and 8A) extending across and over the perimeter wall 14-1. Each groove 32 is configured to accept a horizontal second rebar element 34A or a second tensioning cable 34B extending across each of the external and internal lunate shapes 16, 22.

In addition to the groove(s) 28, the element body 12 may include a sloped or concave wall relief 28A (shown and identified in FIGS. 1A and 3A) and 32A (shown in FIG. 6). The wall relief 28A is configured to generate clearance for the first rebar element 30A or the first tensioning cable 30B placed across the concave bend of the internal lunate shape 22 of the masonry element 10, 20. The grooves 28 may be arranged in a number of predefined alternate orientations relative to the external/internal lunate shape 16/22, as indicated by line marks G shown in FIG. 6, to permit various positioning of the masonry elements 10, 20, such as in corners, in the masonry structure 100. The grooves 32 in the bottom surface 14-3 may extend through the perimeter wall 14-1 to accommodate the second element 34A or the second tensioning cable 34B. Alternatively, the structural masonry elements 10, 20 may be manufactured with the grooves 32 ending in blind holes. In such an embodiment, the structural masonry elements 10, 20 may include impressions 35 inscribed into the perimeter wall 14-1 to indicate material needing to be removed from the perimeter wall for clearance when the second rebar element 34A or the second tensioning cable 34B is certain to be used with the particular masonry element.

The first and second tensioning cables 30B, 34B laid inside the respective grooves 28, 32 generally constitute a cable tensioning system intended to enhance load resistance of walls, columns, arches, etc. in the mortarless masonry structure 100. The grooves 28, 32 may additionally have a shape particularly defined to encapsulate and retain anchors (to be discussed below) of the respective first and second tensioning cables 30B, 34B. External forces are distributed across individual blocks by a chain reaction through the cable tensioning system such that the tensioning cable(s) 30B, 34B tie individual masonry elements 10, 20 and thus provide resistance to damage of the host structure. For example, when the mortarless masonry structure 100 is subjected to vibration, the cable tensioning system serves to maintain masonry element contact within respective interlocking masonry joints J1 and ensures even distribution of forces across the entire mortarless masonry structure 100.

As shown in at least FIGS. 3 and 8, the element body 12 may additionally define a fillet relief 36 in each corner 22-1 and 22-2 of the internal lunate shape 22. The fillet relief 36 is configured to accept a vertical third rebar element 38A or a third tensioning cable 38B (shown in FIGS. 3 and 10) extending along and generally parallel to the perimeter wall 14-1. In the embodiments of FIGS. 3A, 8A, 11A, the element body may accept the vertical third rebar element 38A or the third tensioning cable 38B through the internal lunate shape 22 (shown in FIG. 11A) and thus either include or be devoid of fillet reliefs 36. The rebar elements 30A, 34A, 38A may be constructed from a rigid material, such as steel or fiberglass. The tensioning cables 30B, 34B, 38B may be constructed from a flexible, high strength, and corrosion resistant material, such as stainless steel.

As shown in FIG. 2, the perimeter wall 14-1 may include an outer section 40 having a first slanted surface 42. The first slanted surface 42 defines a generally conoid or cone-like shape of the masonry element's top portion for water shedding. The resultant conoid shape is intended to minimize the possibility of moisture entering the interlocking masonry joint J1 between the structural masonry elements 10 and 20 in the mortarless masonry structure 100. The first slanted surface 42 may intersect the top surface 14-2 on a radius having a magnitude of 3.14 inches with its center at the longitudinal axis Z and intersect the vertical perimeter wall 14-1 at 0.75 inches from the top surface. Different embodiments of the first slanted surface 42 are shown in respective FIGS. 9 and 9A.

As shown in FIG. 9, the first slanted surface 42 may have a compound-angle profile intended to approximate the generally concave profile, described above. Such a compound-angle first slanted surface 42 may include a first slanted surface section 42-1 arranged at a first angle θ1 relative to the longitudinal axis Z, a second slanted surface section 42-2 arranged at a second angle θ2 relative the longitudinal axis Z, and a third slanted surface section 42-3 arranged at a third angle θ3 relative the longitudinal axis Z. The third angle θ3may be greater than the second angle θ2and the second angle θ2 may be greater than the first angle θ1. In a non-limiting example, the first angle θ1 may be in a range of 10-30 degrees, the second angle θ2 may be in a range of 30-60 degrees, and the third angle θ3 may be in a range of 60-80 degrees. Alternatively, the first slanted surface 42 may be approximated by a straight line through the overall height H1 and arranged at a resultant angle θR relative to the vertical perimeter wall 14-1 in a range of 45-55 degrees. In a separate embodiment shown in FIG. 9A, the first slanted surface 42 may have a generally concave profile between the top surface 14-2 and the vertical perimeter wall 14-1 defined by a constant radius R3 having a magnitude of 0.62 inches.

With continued reference to FIGS. 9 and 9A, the bottom surface 14-3 may be inset relative to the perimeter wall 14-1 along the longitudinal axis Z toward the top surface 14-2. The element body 12 may include an inner section 44 having a second slanted surface 46 defining an inclined transition and a cone-like shape between the perimeter wall 14-1 and the inset bottom surface 14-3. The second slanted surface 46 is configured to interface with and nest a corresponding compound-angle first slanted surface 42 of another analogous masonry element engaging the subject masonry element 10 from below. Specifically, when the analogous second interfacing masonry element, such as the masonry element 20, is arranged against the bottom surface 14-3 of the masonry element 10, the first slanted surface 42 nests inside the second slanted surface 46 and thereby provides a tapered or conoid second interlocking masonry joint J2, as shown in FIG. 10. The second slanted surface 46 may be disposed at an angle substantially matching the resultant angle θR of the first slanted surface 42. Each of the first and second slanted surfaces 42, 46 is additionally intended to have a substantially matching overall height H1 (shown in FIGS. 9 and 9A) along the longitudinal axis Z sufficient to engage and interlock with one another, i.e., such that a pair of masonry elements may interface from above or below.

The second interlocking masonry joint J2 permits secure interlinking and stacking of structural masonry elements, e.g., masonry elements 10 and 20, without requiring use of binding mortar. In other words, integrity of the masonry structure 100 relies primarily on the interlocking provided by the first and second masonry joints J1, J2, not on addition of mortar between individual elements. Accordingly, the second interlocking masonry joint J2 permits the masonry elements 10 and 20 to be stacked and interlocked for generating the mortarless masonry structure 100. The resultant internal concavity of the first slanted surface 42 relative to the second slanted surface 46 is intended to facilitate secure nesting and centering of stacked masonry elements 10, 20 and retention of the tapered second interlocking masonry joint J2. A diametral offset of 0.005 inches may be employed on intersection points of the second slanted surface 46 with the vertical perimeter wall 14-1 and the bottom surface 14-3 relative to the intersection points of the first slanted surface 42. Such an offset may ensure a reliable clearance fit of adjacent masonry elements in a column of the resultant masonry structure 100 and also provide space for an adhesive therebetween.

Together, the spherical first interlocking masonry joint J1 and the second interlocking masonry joint J2 are at the root of the “Roundbond Clutchlock” principle. The interlocking masonry joints J1, J2 permit creation of mortarless masonry structures having various contours, heights, and profiles. Additionally, the spherical first interlocking masonry joint J1 and the second interlocking masonry joint J2 permit the resultant mortarless masonry structure 100 to effectively withstand considerable levels of seismic activity. Specifically, the spherical first interlocking masonry joint J1 and the second interlocking masonry joint J2 may allow individual structural masonry elements, e.g., masonry elements 10 and 20, to shift in response to vibrations in the earth's crust without permanent damage to the masonry structure 100.

In addition to the masonry elements 10 and 20, the mortarless masonry structure 100 is intended to include a plurality of other masonry elements configured to interface according to the general “Roundbond Clutchlock” principle described above. Typically, embodiments of the mortarless masonry structure 100 will include some number of masonry elements 10 and 20 arranged in one or more columns or stacks 102 (shown in FIGS. 11 and 11A). As described above, the mortarless masonry structure 100 may include reinforcement and tie-in features, such as the horizontal first rebar element(s) 30A, first tensioning cable(s) 30B, second rebar element 34A, the second tensioning cable 34B, the vertical third rebar element 38A, and/or the third tensioning cable 38B. Some of the subject reinforcement and tie-in features may be used for interconnecting multiple stacks 102 to further strengthen the subject structure. The masonry structure 100 may employ as many individual rebar elements 30A, 34A, 38A and/or as many tensioning cables 30B, 34B, 38B as necessary to generate a robust structure.

When the masonry elements 10 and 20 have been arranged in multiple stacks 102, as shown in FIGS. 11 and 11A, the grooves 28 and 32 of adjacent masonry elements 10 and 20 cooperate to encapsulate the respective rebar element 30A, 34A or tensioning cable 30B, 34B. Additionally, the vertical third rebar element 38A or the third tensioning cable 38B passing through the fillet relief 36 in the corners 22-1 and 22-2 of the internal lunate shape 22 in at least some of the masonry elements 10, 20 arranged in a particular stack 102 will further strengthen the subject stack. Each of the first tensioning cables 30B and the second tensioning cables 34B may extend through a portion of or through an entire individual row 104 (shown at least in FIG. 5). Each tensioning cable 30B, 34B may be secured between individual masonry elements 10 and 20 via a respective anchor 48 (shown in FIGS. 11 and 11A). Such an anchor 48 may be configured as a stainless-steel sleeve arranged within the grooves 28 and 32, embedded or captured between two adjacent masonry elements 10, 20 in a particular stack 102.

With continued reference to FIGS. 11 and 11A, in addition to the anchor 48, each tensioning cable 30B, 34B may include one or more washers 50 serving as a locator and a guide for a specific cable. Each washer 50 may be formed from stainless-steel. Each washer 50 is configured to be embedded between adjacent masonry elements 10, 20 arranged in adjacent rows 104 of a particular stack 102. In other words, a specific tensioning cable 30B, 34B is intended to be threaded through one or more washers 50 such that each subject metal washer will be arranged in the same row 104 as the particular cable's anchor 48. The masonry structure 100 may employ as many individual tensioning cables 30B, 34B in separate rows 104 as deemed necessary for the structure's integrity, and each cable may employ as many washers 50 and anchors 48 as necessary to achieve the desired outcome.

As shown in FIG. 11, the mortarless masonry structure 100 may also include a plurality of masonry finishing blocks 52. Each finishing block 52 includes a perimeter wall 52-1, as well as a top surface 52-2 and a bottom surface 52-3, each having a respective external lunate shape 16. Each of the masonry finishing blocks 52 is configured to be mounted to and interface with the top surface 14-2 of the final or highest masonry element 10, 20. Specifically, the bottom surface 52-3 of each masonry finishing block 52 includes a respective second slanted surface 46 configured to engage and interface with the masonry element 10, 20 located below and nest the compound-angle first slanted surface 42 thereof. Each masonry finishing block 52 is a continuous, solid part characterized by an absence of through holes between the top surface 52-2 and the bottom surface 52-3. Depending on a particular embodiment of the finishing block 52, the finishing block body may have a height H in a range of 2-6 inches. As a result, the masonry finishing blocks 52 may be employed to cover and seal, for example from moisture and/or debris, the hollow sections 24 of the plurality of masonry elements arranged in the stack below.

With reference to each of FIGS. 11 and 11A, the mortarless masonry structure 100 may additionally include a plurality of base masonry blocks 54 configured to be mounted to a structural foundation 106. Each base block 54 includes a perimeter wall 54-1 having a respective external lunate shape 16, along with a top surface 54-2 and a bottom surface 54-3, each having a respective external lunate shape 16. Each of the base masonry blocks 54 is intended to interface with one of the masonry elements 10, 20 in the bottom row of a particular stack 102. Furthermore, adjacent base masonry blocks 54 are configured to interconnect with one another. Specifically, the external lunate shape 16 of each masonry base block 54 is configured to interface with and nest another interfacing masonry base block to thereby generate a base masonry layer 108. Additionally, the top surface 54-2 of each masonry base block 54 is configured to interface with and nest within the bottom surface 14-3 of one of the masonry elements 10, 20, while the bottom surface 54-3 of each masonry base block is configured to interface with the structural foundation 106. Depending on a particular embodiment of the base block 54, the base block body may have a height H in a range of 2-6 inches.

Specifically configured fasteners (not shown), such as bolts, may be used to attach and fix each masonry base block 54 to the structural foundation 106. To accept such fasteners, each masonry base block 54 may define at least one first aperture 56 extending perpendicular to each of the top and bottom surfaces 54-2, 54-3. As shown in FIG. 11, each masonry base block 54 may additionally define one or more second apertures 58 extending perpendicular to each of the top and bottom surfaces 54-2, 54-3. The second aperture(s) 58 are configured to accept the vertical third rebar element 38A or the third tensioning cable 38B extending through at least one of the plurality of masonry elements 10, 20 located above the masonry base block 54 and thereby strengthen the masonry structure 100. Each of the third tensioning cables 38B may extend vertically through either a portion of or an entire individual stack 102 and be secured within individual masonry elements 10 and 20, masonry finishing blocks 52, and/or base blocks 54 via respective anchor(s) 48 and washer(s) 50. The second aperture(s) 58 may be applied to each of the embodiments of masonry base blocks 54 shown in FIG. 11 and in FIG. 11A.

As shown in FIG. 5, at least a section of the masonry structure 100 may be configured as a generally straight wall layout 112 when viewed in a horizontal X-Y plane. Also, at least a section of the masonry structure 100 may be configured as a curved wall layout 114 (shown in FIG. 7) when viewed in the horizontal X-Y plane. The straight wall or curved wall layouts 112, 114 of the masonry structure 100 may include a column of masonry direction-changing blocks 60, shown in FIGS. 12, 13, and 15. As shown in FIG. 12, each masonry direction-changing block 60 (shown in FIG. 17A) includes a perimeter wall 60-1 having a double-concave or bidirectional external lunate shape 62, along with a top surface 60-2 and a bottom surface 60-3. The bidirectional external lunate shape 62 is defined by the first circle C1with the first radius R1 having diametrically opposing symmetrical lenses 18 cut away therefrom (shown in FIG. 13).

Direction-changing blocks 60 may be used to control general curvature of the masonry structure 100 walls.

The straight wall layout 112 or the curved wall layout 114 of the masonry structure 100 may include corner blocks 64, as shown in FIGS. 5 and 17, for example, stacked in columns. As shown in FIG. 14, each corner block 64 includes a perimeter wall 64-1 having a fully (360-degree) cylindrical shape 66, along with a top surface 64-2 and a bottom surface 64-3. The cylindrical shape 66 of the corner block 64 is defined by the first circle C1having the first radius R1 (shown in FIG. 5) and may include a circular open inner space 68 (shown in FIG. 14). The corner block 64 may have an overall height of 6.00 inches, an outer diameter of 8.00 inches, an inside diameter of 4.50 inches, and a resultant wall thickness of 1.75 inches. The cylindrical shape 66 of the corner blocks 64 may be configured to provide nesting transitions at various angles between adjacent or intersecting walls. A column of corner blocks 64 is intended to interface with an adjacent column of masonry elements 10, 20 to provide a respective nesting transition. Such a nesting transition between each masonry element 10, 20 and a respective corner block 64 is enabled via the complementary surfaces of the external lunate shape 16 and the fully cylindrical shape 66.

Stacked columns of corner blocks 64 may be particularly useful for providing a transition between two adjacent walls arranged at an angle equal to or smaller than 90 degrees relative to one another. Also, columns of corner blocks 64 may be used to define door and/or window openings in the masonry structure 100. Each corner block 64 may include grooves 28, 32 to accommodate and capture therebetween the horizontal first tensioning cable 30B and the horizontal second tensioning cable 34B. Additionally, the vertical third rebar element 38A or the vertical third tensioning cable 38B may extend through the circular open inner space 68, as shown in FIG. 16, to strengthen the corresponding column of corner blocks 64. Although not specifically shown, the horizontal first rebar elements 30A and/or the first tensioning cables 30B may also be used with the corner blocks 64 analogously to their usage with elements 10, 20.

As shown in FIG. 15, walls of the masonry structure 100 may additionally include single-piece multi-section blocks 72, shown in FIGS. 16, 17, 18, and 19, having multiple (two, three, or more) subsections. For example, the single-piece multi-section block 72 may include two subsections (base block embodiment shown in FIG. 16 and interfacing block embodiment shown in FIG. 17), and thus configured to occupy the space of two adjacent individual elements 10, 20 nested within the corresponding symmetrical lens 18. In another embodiment, the single-piece multi-section block 72 may include three subsections (base block embodiment shown in FIG. 18 and interfacing block embodiment shown in FIG. 19), and thus configured to occupy the space of three adjacent individual elements 10, 20 nested within the corresponding symmetrical lenses 18. Each single-piece multi-section block 72 is formed as a unitary or integral element, effectively combining multiple subsections, each subsection generally corresponding to an individual masonry element, such as the element 10 and/or the corner block 64. However, rather than individual masonry elements 10, 20 being joined during construction of the masonry structure 100, multiple subsections of each single-piece multi-section block 72 are combined into an integral element during forming of the subject block.

Each single-piece multi-section block 72 may include grooves 28, 32 (on the top and bottom sides, respectively) to accommodate and capture therebetween the horizontal first tensioning cable 30B and the horizontal second tensioning cable 34B. Additionally, the vertical third rebar element 38A or the vertical third tensioning cable 38B may extend through an open inner space 74 of single-piece multi-section blocks 72 (shown in FIGS. 17 and 19) to strengthen a corresponding column of single-piece multi-section blocks. Although not specifically shown, the horizontal first rebar elements 30A and/or the first tensioning cables 30B may also be used with the single-piece multi-section blocks 72 analogously to their usage with elements 10, 20 and corner blocks 64. Furthermore, although not shown, the corner blocks 64 as well as the single-piece multi-section blocks 72 may be accompanied by correspondingly shaped (in the top view) finishing blocks having a solid, lid-or cap-like construction devoid of open inner spaces. In other words, each such finishing block would have a mating contour matching the top surface of the particular block 64 or 72. Therefore, appropriately shaped finishing blocks may be placed over the top of respective corner blocks 64 and single-piece multi-section blocks 72 to interface therewith and cover the respective inner spaces 68, 74 from the elements.

Furthermore, as shown in FIG. 20, at least a section of the masonry structure 100 may be configured as a vertically oriented arc 116, i.e., an arc arranged in the X-Z plane. As shown, the arc 116 may include the masonry direction-changing block 60 positioned to link nearby masonry elements 10 or 20 and enable a reliable connection therebetween. For aesthetics, the masonry direction-changing block 60 may be positioned at the apex of the arc 116 shape. The arc 116 structure may be strengthened via the first and/or the second tensioning cables 30B, 34B. For enhanced integrity of the masonry structure 100, the structure may further include an adhesive 118 (shown in FIG. 11) applied in at least one of the first and second interlocking masonry joints J1 and J2. Consequently, the adhesive 118 may also be applied in interfaces between the masonry elements 10, 20, masonry finishing blocks 52, masonry base blocks 54, the direction-changing block 60, corner blocks 60, and single-piece multi-section blocks 72. Specifically, the adhesive 118 may also be applied between the bottom surface 54-3 of each masonry base block 54 and the structural foundation 106 to seal off moisture.

Overall, masonry elements 10 and 20, finishing block 52, base block 54, direction-changing block 60, and corner block 64 are uniquely shaped high-density concrete blocks, panels, and tiles for use as structural and insulating building material in the Interlocking Roundbond Clutchlock system. The masonry elements 10 and 20 serve as the main building blocks for structural walls employing the “Roundbond Clutchlock” principle. Structural walls using the Roundbond Clutchlock system may have significantly reduced mass and thickness as compared to more traditionally constructed walls. The shape of Roundbond Clutchlock elements permits structural walls of various geometries to be built without the use of expensive mechanization equipment. At its core, the Roundbond Clutchlock system employs interlocking masonry joints J1, J2 to enable nesting interconnections between adjacent building blocks and elements to generate a mortarless masonry structure 100. Additionally, structures using the Roundbond Clutchlock system are well-suited to geographical regions with high seismic activity. Specifically, by distributing shocks and vibrations under such conditions along load-bearing walls and columns, the Roundbond Clutchlock system minimizes possibility of damage to the overall structure.

The detailed description and the drawings or figures are supportive and descriptive of the disclosure, but the scope of the disclosure is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims. Furthermore, the embodiments shown in the drawings or the characteristics of various embodiments mentioned in the present description are not necessarily to be understood as embodiments independent of each other. Rather, it is possible that each of the characteristics described in one of the examples of an embodiment can be combined with one or a plurality of other desired characteristics from other embodiments, resulting in other embodiments not described in words or by reference to the drawings. Accordingly, such other embodiments fall within the framework of the scope of the appended claims.

Claims

1. A masonry element comprising:

an element body having a perimeter wall defined by a height and having parallel top and bottom surfaces, each of the top and bottom surfaces having an external lunate shape;
wherein: the external lunate shape is defined by a material section resulting from a symmetrical lens cut away from a first circle having a first radius, the symmetrical lens is a result of an intersection of the first circle with a second circle having a second radius equivalent to the first radius; a distance between a center of the first circle and a center of the second circle is greater than each of the first and second radii; and the external lunate shape is configured to nest an analogous interfacing masonry element within the symmetrical lens and thereby provide a spherical first interlocking masonry joint.

2. The masonry element of claim 1, wherein each of the top and bottom surfaces additionally has an internal lunate shape, thereby defining a hollow section arranged concentrically with and oriented same as the external lunate shape, and wherein the internal lunate shape is configured to accept a reinforcement material therein.

3. The masonry element of claim 2, wherein the top surface defines a groove configured to accept a horizontal first rebar element or a first tensioning cable extending across each of the external and internal lunate shapes.

4. The masonry element of claim 2, wherein the bottom surface defines a groove configured to accept a horizontal second rebar element or a second tensioning cable extending across each of the external and internal lunate shapes.

5. The masonry element of claim 2, wherein the element body additionally defines a fillet relief in a corner of the internal lunate shape configured to accept a vertical third rebar element or a third tensioning cable extending along the perimeter wall.

6. The masonry element of claim 1, wherein:

the element body includes a longitudinal axis;
the perimeter wall is arranged along the longitudinal axis; and
the perimeter wall includes an outer section having a first slanted surface.

7. The masonry element of claim 6, wherein the first slanted surface has a concave profile.

8. The masonry element of claim 6, wherein the bottom surface is inset relative to the perimeter wall toward the top surface, and wherein the element body includes an inner section having a second slanted surface between the perimeter wall and the inset bottom surface configured to interface with and nest a first slanted surface of an analogous second interfacing masonry element when the analogous second interfacing masonry element is arranged against the bottom surface to nest therein and thereby provide a tapered second interlocking masonry joint.

9. The masonry element of claim 1, wherein the element body is provided from high-density pressed concrete formed under a 12-14 MPa load.

10. The masonry element of claim 1, wherein each of the first and second radii is 4.00 inches, and the distance between the center of the first circle and the center of the second circle is 5.6 inches.

11. A mortarless masonry structure comprising:

a plurality of masonry elements, wherein each masonry element includes:
an element body having a perimeter wall defined by height and having parallel top and bottom surfaces, each of the top and bottom surfaces having an external lunate shape;
wherein: the external lunate shape is defined by a material section resulting from a symmetrical lens cut away from a first circle having a first radius, the symmetrical lens is a result of an intersection of the first circle with a second circle having a second radius equivalent to the first radius; a distance between a center of the first circle and a center of the second circle is greater than each of the first and second radii; the external lunate shape is configured to nest an analogous interfacing masonry element within the symmetrical lens and thereby provide a spherical first interlocking masonry joint therebetween; and at least one of the top surface and the bottom surface is configured to nest therein a second interfacing masonry element and thereby provide a tapered second interlocking masonry joint.

12. The mortarless masonry structure of claim 11, wherein each of the top and bottom surfaces additionally have an internal lunate shape, thereby defining a hollow section arranged concentrically with and oriented same as the external lunate shape, and wherein the internal lunate shape is configured to accept a reinforcement material therein.

13. The mortarless masonry structure of claim 12, further comprising a horizontal first rebar element or a first tensioning cable, wherein the top surface defines a groove configured to accept the horizontal first rebar element or the first tensioning cable extending across each of the external and internal lunate shapes.

14. The mortarless masonry structure of claim 12, further comprising a horizontal second rebar element or a second tensioning cable, wherein the bottom surface defines a groove configured to accept a horizontal second rebar element or a second tensioning cable extending across each of the external and internal lunate shapes.

15. The mortarless masonry structure of claim 12, further comprising a plurality of masonry finishing blocks, each configured to be mounted to and cover the hollow section in one of the plurality of masonry elements.

16. The mortarless masonry structure of claim 11, further comprising a plurality of base masonry blocks configured to be mounted to a structural foundation and interface with at least some of the plurality of masonry elements;

wherein: each base block includes top and bottom surfaces, each of the top and bottom surfaces of the base masonry blocks having an external lunate shape; the external lunate shape of the masonry base block is configured to interface with and nest a masonry base block to thereby generate a base masonry layer; the top surface of each masonry base block is configured to interface with and nest within the bottom surface of one of the plurality of masonry elements; and the bottom surface of each masonry base block is configured to interface with the structural foundation.

17. The mortarless masonry structure of claim 16, wherein each masonry base block additionally defines a first aperture extending perpendicular to each of the top and bottom surfaces and configured to accept a fastener to thereby attach the masonry base block to the structural foundation.

18. The mortarless masonry structure of claim 16, further comprising a vertical third rebar element or a third tensioning cable, wherein each masonry base block additionally defines a second aperture extending perpendicular to each of the top and bottom surfaces and configured to accept the vertical third rebar element or the third tensioning cable extending through at least one of the plurality of masonry elements located above the masonry base block and thereby strengthen the masonry structure.

19. The mortarless masonry structure of claim 16, further comprising an adhesive applied to at least one of the first and second interlocking masonry joints and between the bottom surface of each masonry base block and the structural foundation.

20. The mortarless masonry structure of claim 11, wherein at least a section of the masonry structure is configured as a curved wall layout arranged in a horizontal plane.

21. The mortarless masonry structure of claim 11, wherein at least a section of the masonry structure includes a masonry direction-changing block having a bidirectional external lunate shape.

22. The mortarless masonry structure of claim 21, wherein at least a section of the masonry structure is configured as an arc arranged in a vertical plane, and wherein the arc includes the masonry direction-changing block.

23. The mortarless masonry structure of claim 11, wherein at least a section of the masonry structure includes one or more corner blocks, each having a fully cylindrical shape configured to interface with at least one of the masonry elements and thereby provide a nesting transition between adjacent or intersecting walls.

Patent History
Publication number: 20240301684
Type: Application
Filed: Mar 9, 2023
Publication Date: Sep 12, 2024
Inventor: Gerald Berger (Laguna Niguel, CA)
Application Number: 18/181,317
Classifications
International Classification: E04B 2/18 (20060101);