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[0001] This application claims priority to copending U.S. provisional application entitled, “EZ-STACK BUILDING BLOCKS,” having Application Serial No. 60/273,024, filed Mar. 2, 2001, which is entirely incorporated herein by reference.
[0002] The present invention is generally related to construction materials and methods and, more particularly, is related to a building block systems and methods of assembly.
[0003] Various structures, such as mailboxes, planters, and walls are constructed of heavy materials, e.g., bricks or rocks, that are set in mortar. Such structures are typically constructed by stacking the media one piece at a time in the mortar, while the mortar is wet and pasty.
[0004] During this method of construction, each piece of media is positioned by hand into a desired location. Thus, each piece of media must be placed and properly aligned in the wet mortar. As is known, positioning of the media can be difficult, especially where asymmetric media, such as rocks, are used.
[0005] After media has been positioned in mortar, additional wet, pasty mortar typically is placed between adjacently positioned media and on top of the media. This tends to rigidify the structure and enables additional media to be placed. Additionally, during the process of positioning, or “laying,” the media, the mortar typically is given an opportunity to dry to prevent the structure from collapsing as a result of excessive media weight bearing on the wet mortar. Also, excess mortar typically is removed from the media and mortar structure before the mortar has an opportunity to dry completely.
[0006] As is known, the aforementioned “media and mortar” construction process is labor intensive. Additionally, waiting for the mortar to dry during the construction process, as well as the need for manual labor makes this a time consuming and relatively expensive process. The process also tends to waste materials, such as excess mortar that is removed from the structure.
[0007] Based on the foregoing, it should be appreciated that there is a need for improved systems and methods that address the aforementioned and/or other perceived deficiencies and inadequacies of the prior art.
[0008] The present invention provides building systems and methods for assembling media and mortar structures. In this regard, an embodiment of such a system includes a first pre-formed, monolithic block exhibiting indicia of media and mortar about at least a portion of the exterior of the monolithic block.
[0009] Another embodiment of the system includes a first foundation block having a top portion and a bottom portion. The first foundation block has multiple layers. The multiple layers include at least a media layer and an attachment layer. The media layer is defined by a first set of dimensions and is located toward the bottom portion of the first foundation block. The attachment layer is defined by a second set of dimensions and extends from the media layer toward the top portion of the first foundation block. An attachment channel is inset in a surface of the media layer opposing a surface of the media layer from which the attachment layer extends.
[0010] The present invention can also be viewed as providing methods for assembling the building block system. In this regard, one embodiment of such a method, among others, can be broadly summarized by the following steps: providing a first pre-formed, monolithic block exhibiting indicia of media and mortar about at least a portion of the exterior of the monolithic block; providing a second block; and dry-stacking the first pre-formed, monolithic block and the second block to form a structure exhibiting an appearance of being formed of multiple separate media attached together with mortar.
[0011] Another method includes: providing a first foundation block having a top portion and a bottom portion and multiple layers; and providing a second foundation block having a top portion and a bottom portion and multiple layers. The multiple layers of the first foundation block and the second foundation block are at least a media layer and an attachment layer. Each finishing block has a media layer that is defined by a first set of dimensions and is disposed toward the bottom portion the foundation block. Each finishing block also includes an attachment layer that is defined by a second set of dimensions and extends from the media layer toward the top portion of the foundation block. An attachment channel is provided in at least the second foundation block. The second foundation block is stacked on top of the first foundation block such that the attachment layer of the first foundation block is aligned and engaged with the attachment channel of the second foundation block.
[0012] Other systems, methods, features, and advantages of the present invention will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.
[0013] Many aspects of the invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0014]
[0015]
[0016]
[0017]
[0018]
[0019]
[0020] Referring now to the drawings,
[0021] Foundation blocks of the invention can be provided in various shapes and sizes, so that structures of various shapes and sizes can be formed. For example, the foundation blocks can be generally rectangular, as viewed from above (shown in FIGS.
[0022] Referring now to FIGS.
[0023] In some embodiments, the entire foundation block is cast using a relatively homogenous material to form each of the levels or layers into a monolithic structure. Alternatively, one or more of the layers could be separately formed and then fixed or bonded together.
[0024] Foundation block
[0025] A media layer
[0026] The foundation block of FIGS.
[0027] The mortar layer
[0028] An attachment layer
[0029] The foundation block
[0030] As shown in
[0031] The finishing block
[0032] In order to promote secure engagement of a finishing block with a foundation block during stacking, the finishing block
[0033] The present invention also provides methods for assembling media and mortar structures. By way of example, one such method includes: providing a preformed, monolithic block exhibiting indicia of media and mortar about at least a portion of the exterior of the monolithic block; providing a second block; and dry-stacking the pre-formed, monolithic block and the second block to form a structure exhibiting an appearance of being formed of multiple separate media attached together with mortar.
[0034] Another method, which involves assembling a media and mortar structure with blocks, such as those depicted in
[0035] A second foundation block
[0036] Where the media layer
[0037]
[0038] It should be emphasized that the above-described embodiments of the present invention are merely possible examples of implementations merely set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiment(s) of the invention without departing substantially from the spirit and principles of the invention. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present invention and protected by the following claims.