BLOCK INTERLOCKING MODULE BASED (BIM BASED) SYSTEM TO BUILD ARCHITECTURAL STRUCTURES

Title:

BLOCK INTERLOCKING MODULE BASED (BIM BASED) SYSTEM TO BUILD ARCHITECTURAL STRUCTURES

Document Type and Number:

WIPO Patent Application WO/2017/181205

Kind Code:

Abstract:

An improved system to build structures like the walls and columns of a single family residential home or other residential and commercial buildings as well as fences, circular and semi-circular structures and other architectural structures. A system that includes layout units (10-16, 49-64, 93-99), modular building units (1-9, 17-24, 30-48, 81-92, 100-115), the methods to manufacture such as well as the details to build simple structures like Single and Double Whyte Walls (65-66, 67-68 respectively), Single Whyte Arc-Shaped Walls (116-117), Single Whyte Columns (69-70), Double Whyte Wall Corners (71-72), Windows and Door Openings (77-78, 79-80 respectively), etc. (73-74, 75-76 ). The system also includes building units that facilitate the installation of electrical outlets and switches (25-29) and other components (81-83).

Inventors:

MARTINEZ LAZARO A (US)

Application Number:

PCT/US2017/037422

Publication Date:

October 19, 2017

Filing Date:

June 14, 2017

Export Citation:

Click for automatic bibliography generation Help

Assignee:

MARTINEZ LAZARO A (US)

International Classes:

F16B2/06; B62K15/00

Attorney, Agent or Firm:

TADROS, Jacqueline (US)

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Claims:

What is claimed is:

3! M (Block Interlocking Module)

1. A modular building unit adapted for inter-fitting/inter-locking with adjacent building units; said modular building unit comprising: a block formed of a homogenous material and including a pair of parallel rectangular end supporting faces, a pair of parallel rectangular side supporting faces, and parallel rectangular upper and lower supporting faces (for example a 194 x 92 x 57 mm clay brick); and a block interlocking module (BIM) made of polymer including a pair of parallel rectangular end supporting faces, a pair of parallel rectangular side faces, and parallel rectangular upper and lower supporting faces.

2. The upper and lower supporting faces of the block interlocking module (BIM) set forth in claim 1 extends over the entire upper face of the block.

3. The top parallel planar surface set forth in claim 2 has four aligned circular perforations located at the center (if 194 x 92 x 57 mm clay brick) of the BIM. Each preformation goes from one side of the top planar surface to the other side of the planar surface.

4. The top parallel planar surface extending over the entire upper face of the block set forth in claim 2 may have, depending on the model, two additional perforations located on each side of the four aligned circular perforations to save material during the production process. Each preformation goes from one side of the top planar surface to the other side of the planar surface.

5. The block interlocking module (BIM) set forth in claim 1 has two vertical legs attached to each side of the end supporting faces.

6. Each vertical leg set forth in claim 5 has a trapezoidal shape and is placed in a way that forms two dovetail-tails and two dovetail-sockets on each side of the end supporting faces of the block interlocking module.

7. The tails and sockets set forth in claim 6 create a pattern that allows adjacent building units to inter-lock for mounting of adjacent building units in precise horizontal layers with each horizontal layer including a plurality of building units in end to end.

8. Each vertical leg set forth in claim 6 ends in a cylindrical form that creates a pin that locks in one of the four aligned circular perforations set forth in claim 3 of a BIM located in the horizontal layer right below.

9. The four aligned perforations set forth in claim 3 and the pins at the end of each leg set forth in claim 8 are designed in a way that the BIMs lock permanently or lock properly yet disassembling several horizontal layers is possible.

out BI M (Block interlocking Module)

10. A layout block interlocking module (Layout BIM) made of polymer including a pair of parallel rectangular end supporting faces, a pair of parallel rectangular side faces, and parallel rectangular upper and lower supporting faces.

11. The upper and lower supporting faces of the Layout BIM set forth in claim 10 extends over the entire lower face of the block.

12. The parallel planar surface set forth in claim 10 has four aligned circular perforations located at the center of the Layout BIM. Each preformation goes from one side of the top planar surface to the other side of the planar surface.

13. The top parallel planar surface extending over the entire upper face of the Layout BIM set forth in claim 10 may have, depending on the model, two additional perforations located on each side of the four aligned circular perforations to save material during the production process.

14. The Layout BIM set forth in claim 10 has two trapezoidal extensions attached to each side of the end supporting faces set forth in claim 10.

15. Each extension set forth in claim 14 is placed in a way that forms two dovetail-tails and two dovetail-sockets on each side of the layout block interlocking module.

16. The tails and sockets set forth in claim 15 create a pattern that allows adjacent layout units to inter-lock for mounting of adjacent layout units in a precise horizontal layer with the horizontal layer including a plurality of layout units in end to end.

17. A b-BIM with the same characteristics set forth in claims 1 thru 9.

18. The b-BIM has two more vertical legs attached to just one side, the bottom right side, of the side supporting faces set forth in claim 17.

19. Each vertical leg set forth in claim 18 ends in a cylindrical form that creates a pin that locks in one of the four aligned circular perforations set forth in claim 2 of a BIM located in the horizontal layer right below.

I M

20. A C-BIM with the same characteristics set forth in claims 1 thru 4.

21. The C-BIM set forth in claim 16 has four vertical legs attached to one side, the right side, of the side supporting faces set forth in claim 20.

22. Each vertical leg set forth in claim 21 has a trapezoidal shape and is placed in a way that forms two dovetail-tails and two dovetail-sockets on the right side of the C-BIM.

23. The tails and sockets set forth in claim 22 create a pattern that allows adjacent building units to inter-lock for mounting of adjacent building units in precise horizontal layers with each horizontal layer including a plurality of building units in end to end.

24. Each vertical leg set forth in claim 21 ends in a cylindrical form that creates a pin that locks in one of the four aligned circular perforations of a BIM located in the horizontal layer right below.

I M

25. A modular building unit adapted for inter-fitting/inter-locking with adjacent building units; said modular building unit comprising:

An electric block interlocking module (e-BIM) made of polymer including a pair of parallel rectangular end supporting faces, a pair of parallel rectangular side faces, and parallel rectangular upper and lower supporting faces, a pair of parallel rectangular faces extending vertically from each of the end faces, a pair of parallel rectangular faces extending vertically from one side, the right side, of the side face.

26. The pair of parallel rectangular faces extending vertically from one side, the right side, of the side face as set forth in claim 25 has a perforation that allows the installation of a residential grade duplex or single electrical outlet or a residential grade duplex or single electrical switch.

27. The top parallel planar surface extending over the entire upper face of the block set forth in claim 25 may have, depending on the model, two additional perforations located on each side of the four aligned circular perforations to save material during the production process. Each preformation goes from one side of the top planar surface to the other side of the planar surface.

28. The interior of the e-BIM has an electrical outlet box, a 1-gang box that is wide enough for a switch or duplex receptacle.

29. The back of the 1-gan box set forth in claim 28 has a circular perforation that allows the electricians to pass-thru the electric wires to reach the residential grade duplex or single electrical outlet or a residential grade duplex or single electrical switch installed in the e-BIM.

F-B! M

30. An F-BIM with the same characteristics set forth in claims 1 thru 9.

31. The F-BIM has two more vertical legs attached to just one side, the top right side, of the side supporting faces set forth in claim 30.

32. Each vertical leg set forth in claim 31 ends in a cylindrical form that creates a pin that locks in one of the four aligned circular perforations set forth in claim 2 of a BIM located in the horizontal layer right below.

i - B!

33. An i-BIM with the same characteristics set forth in claims 1 thru 4.

34. A block interlocking module (BIM) set forth in claim 33 has two vertical legs attached to one side of the end supporting faces, the top side.

35. Each vertical leg set forth in claim 34 has a trapezoidal shape and is placed in a way that forms two dovetail-tails and two dovetail-sockets on each side of the end supporting faces of the block interlocking module.

36. The tails and sockets set forth in claim 35 create a pattern that allows adjacent building units to inter-lock for mounting of adjacent building units in precise horizontal layers with each horizontal layer including a plurality of building units in end to end.

37. Each vertical leg set forth in claim 35 ends in a cylindrical form that creates a pin that locks in one of the four aligned circular perforations set forth in claim 2 of a BIM located in the horizontal layer right below.

38. The four aligned perforations set forth in claim 33 and the pins at the end of each leg set forth in claim 8 are designed in a way that the BIMs lock permanently or lock properly yet disassembling several horizontal layers is possible. J-B I M

39. A J-BIM with the same characteristics set forth in claims 33 thru 38.

40. The J-BIM has two more vertical legs attached to just one side, the bottom left side, of the side supporting faces set forth in claim 39.

41. Each vertical leg of the J-BIM ends in a cylindrical form that creates a pin that locks in one of the four aligned circular perforations set forth in claim 39 of a BIM located in the horizontal layer right below.

L-3 I M

42. A L-BIM with the same characteristics set forth in claims 33 thru 38.

43. The L-BIM has two more vertical legs attached to just one side, the bottom right side, of the side supporting faces set forth in claim 42.

44. Each vertical leg of the L-BIM ends in a cylindrical form that creates a pin that locks in one of the four aligned circular perforations set forth in claim 42 of a BIM located in the horizontal layer right below

X-S I

45. A X-BIM with the same characteristics set forth in claims 20 thru 24.

46. The C-BIM set forth in claim 45 has four additional vertical legs attached to one side, the left side, of the side supporting faces forth in claim 45.

47. Each vertical leg set forth in claim 46 has a trapezoidal shape and is placed in a way that forms two dovetail-tails and two dovetail-sockets on the left side of the X-BIM.

48. The tails and sockets set forth in claim 45 and 46 create a pattern that allows adjacent building units to inter-lock for mounting of adjacent building units in precise horizontal layers with each horizontal layer including a plurality of building units in end to end.

Lavout b-BI M

49. A Layout b-BIM (Layout b-BIM) with the same characteristics set forth in claims 10 thru 16.

50. The Layout b-BIM set forth in claim 49 has two additional trapezoidal extensions attached to just one side, the bottom right side, of the side supporting faces set forth in claim 49.

Layout C-BI M

51. A Layout C-BIM with the same characteristics set forth in claims 10 thru 13.

52. The Layout C-BIM set forth in claim 51 has four trapezoidal extensions attached to one side, the right side, of the side supporting faces set forth in claim 51.

53. Each extension set forth in claim 52 is placed in a way that forms two dovetail-tails and two dovetail-sockets on each side of the layout block interlocking module.

54. The tails and sockets set forth in claim 53 create a pattern that allows adjacent layout units to inter-lock for mounting of adjacent layout units in a precise horizontal layer with the horizontal layer including a plurality of layout units in end to end.

Layout F-BI M

55. A Layout F-BIM with the same characteristics set forth in claims 10 thru 16.

56. The Layout F-BIM set forth in claim 52 has two trapezoidal extensions attached to just one side, the top right side, of the side supporting faces set forth in claim 55.

Layout i-BI

57. A Layout i-BIM with the same characteristics set forth in claims 10 thru 13.

58. The Layout i-BIM set forth in claim 57 has two trapezoidal extensions attached to one side, the top side, of the end supporting faces set forth in claim 57.

59. Each extension set forth in claim 58 is placed in a way that forms two dovetail-tails and two dovetail-sockets on each side of the layout block interlocking module.

60. The tails and sockets set forth in claim 59 create a pattern that allows adjacent layout units to inter-lock for mounting of adjacent layout units in a precise horizontal layer with the horizontal layer including a plurality of layout units in end to end.

Layout j-Bi M

61. A Layout J-BIM with the same characteristics set forth in claims 57 thru 60.

62. The Layout J-BIM set forth in claim 61 has two additional trapezoidal extensions attached to just one side, the bottom left side, of the side supporting faces set forth in claim 61. out L-B!

63. A Layout L-BIM with the same characteristics set forth in claims 57 thru 60.

64. The Layout L-BIM set forth in claim 61 has two additional trapezoidal extensions attached to just one side, the bottom right side, of the side supporting faces set forth in claim 63. igle Wythe Wall

65. A Single Wythe Wall formed of multiple layers which in turn are formed by a plurality of inter- fitting/inter-locking BIMs as set forth in claims from 1 thru 9 and a single layout layer formed by a plurality of Layout BIMs of as set forth in claims from 10 thru 16.

66. A method of forming a generally vertical single wythe wall wherein:

The first layer of the wall is the layout layer built utilizing a plurality of Layout BIMs. The first Layout BIM of the layout layer is placed (or anchored) to the floor, then its bottom tails and pins are interlocked to the top tails and pins of the second Layout BIM, which in turn is interlocked by its bottom tails and pins to the top tails and pins of yet another Layout BIM. Every BIM thereafter follows the same installation pattern forming a row of Layout BIMs that can be extended for as much distance as necessary.

The first layer of the wall (the layout layer) can be anchored to the floor if necessary. All subsequent wall layers are made of a plurality of BIMs where: the pins set forth in claim 8 lock in one of the four aligned circular perforations set forth in claim 2 (or 12 if Layout BIM if the first BIM layer) of a BIM (or Layout BIM if the first BIM layer) located in the horizontal layer right below. each BIM interlocks by its bottom tails and pins to the top tails and pins of the next BIM down the row.

Two parallel Single Wythe Wall separated at a distance of half a building unit (or one building unit) provide the space necessary to install the plumbing of residential and commercial building. Double Wythe Wall

67. A two wythes wall formed of multiple layers which in turn are formed by a plurality of inter- fitting/inter-locking b-BIMs (as set forth in claims from 17 thru 19) and F-BIMs (as set forth in claims from 30 thru 32) and a single layout layer formed by a plurality of Layout b-BIMs (of as set forth in claims from 49 thru 20) and Layout F-BIMs (of as set forth in claims from 55 thru 56).

68. A method of forming a generally vertical double wythe wall wherein:

The first layer of the wall is the layout layer and it is built utilizing a plurality of Layout b-BIMs and Layout F-BIMs sets wherein each layout set is created by rotating the Layout b-BIM 180 degrees and interlocking its side tails and pins with the side tails and pins of the Layout F-BIM.

The first layer of the wall (the layout layer) can be anchored to the floor if necessary.

The end of end of each side of the layout layer of the double wythe wall is ended with a Layout C- BIM (as set forth in claims from 51 thru 54) rotated 90 degrees.

All subsequent wall layers are built utilizing a plurality of b-BIMs and F-BIMs sets wherein each set in created by rotating the b-BIM 180 degrees and interlocking its side tails and pins with the side tails and pins of the F-BIM.

The end of each side of the layer built with a plurality of b-BIMs and F-BIMs sets will alternate between:

a. Ending with a C-BIM (as set forth in claims from 20 thru 24) rotated 90 degrees

b. A set built with one J-BIM (as set forth in claims from 39 thru 41) with its side tails and pins interlocked with one L-BIM (as set forth in claims from 42 thru 44).

A Double Wythe Wall has an opening between the two vertical BIM layers that form that wall that allows the installation of the wiring (whether electrical, video, audio or data). For example, The omex brand of Non-Metallic Building Wire ("NM") originated in 1922 developed by the former Rome Wire Company, in combination with the e-BIM can be utilized to perform the electrical wiring of a residential or commercial building that utilizes Double Wythe Wall as part of its structure. Singl Wythe Column

69. A single wythe column formed of multiple layers which in turn are formed by a plurality of inter- fitting/inter-locking BIMs (as set forth in claims from 1 thru 9), J-BIMs (as set forth in claims from 39 thru 41) and L-BIM (as set forth in claims from 42 thru 44) as well as a single layout layer formed by a plurality of Layout BIMs (of as set forth in claims from 10 thru 16), Layout J-BIMs (of as set forth in claims from 61 thru 62) and Layout L-BIMs (of as set forth in claims from 63 thru 64).

70. A method of forming a generally vertical Single Wythe Column wherein:

The first layer of the single wythe is the layout layer and it is built starting with a Layout L-BIM (1^st element in the layout) interlocked by its top tails and pins with the bottom tails and pins of a Layout BIM (2^nd element in the layout), which in turn is interlocked by its top tails and pins with the top tail and pins of a Layout J-BIM (3^rd element in the layout), which in turn is interlocked by its side tails and pins with the top tails and pins of a Layout BIM (4^th element in the layout), which in turn is interlocked by its bottom tails and pins to the top tails and pins to the top tails and pins of yet another Layout BIM (5^th element in the layout), which in turn is interlocked by its bottom tails and pins to the side tails and pins of a Layout L-BIM (6^th element in the layout), which in turn is interlocked by its top tails and pins to the top tails and pins of a Layout BIM (7^th element in the layout), which in turn is interlocked by its bottom tails and pins to the top tails and pins of a Layout J-BIM (8^th element in the layout), which in turn is interlocked by its side tails and pins to the bottom tails and pins of a Layout BIM (9^th element in the layout), which in turn is interlocked by its top tails and pins to the bottom tails and pins of yet another Layout BIM (10^th element in the layout), which in turn is interlocked by its top tails and pins to the side tails and pins of the Layout L-BIM that started the column layout (the 1^st element in the layout).

The first layer of the column (the layout layer) can be anchored to the floor if necessary.

The actual square footage of the column can be increased by adding Layout BIMs in the same quantity to each opposite side of the layout layer.

The second layer (the first layer created with several of the BIM types) is built starting with a J- BIM (1^st element of the first BIM row) where the two pins located at the bottom of the two side legs of the J-BIM lock with two of the four circular perforations of the Layout L-BIM (1^st element in the layout) right below and the two pins located at the bottom of the two top legs of the J-BIM lock with two of the four circular perforations of the Layout BIM (10^th element in the layout).

If additional Layout BIMs were added to the layout layer then additional BIM will have to be added in the same quantity to the opposite side of the second layer (the first layer created with several of the BIM types).

The third layer of the single wythe (the second layer created with several of the BIM types) can be created by forming a BIM layer like the one described above and rotating that layer until the pins located at the bottom of the two side legs of a L-BIM lock with the four circular perforations of the 1^st element of the first BIM row (a J-BIM).

All subsequent layers of the single wythe column are created repeating the steps detailed to create the second and third layer of the column.

ub!e ythe Wail Corner

71. A double wythe wall corner formed of multiple layers which in turn are formed by a plurality of inter-fitting/inter-locking BIMs (as set forth in claims from 1 thru 9), L-BIM (as set forth in claims from 42 thru 44), b-BIMS, F-BIMS and J-BIMs (as set forth in claims from 39 thru 41), as well as a single layout layer formed by a Layout BIMs (of as set forth in claims from 10 thru 16), a Layout L- BIM, a Layout b-BIM, a Layout F-BIM and a Layout J-BIMs (of as set forth in claims from 61 thru 62).

72. A method of forming a generally vertical double wythe wall corner wherein:

The first layer of the double wythe corner the layout layer and it is built starting with a Layout L- BIM (1st element in the layout) interlocked by its top tails and pins with the bottom tails and pins of a Layout b-BIM (2nd element in the layout), which in turn is interlocked by its side tails and pins to the side tails and pins of a Layout F-BIM (3^rd element of the layout) rotated 180 degrees, which in turn is interlocked by its top tails and pins to the side tails and pins of a Layout J-BIM (4^th element of the layout) rotated 90 degrees. Finally a Layout BIM (5^th element of the layout) is interlocked by its bottom tails and pins to the side tails and pins of the 1^st element of the layout (Layout L- BIM). The second layer (the first layer created with several of the BIM types) is built starting with a J- BIM (1st element of the first BIM row) where the two pins located at the bottom of the two side legs of the J-BIM lock with two of the four circular perforations of the Layout L-BIM (1st element in the layout) right below and the two pins located at the bottom of the two top legs of the J-BIM lock with two of the four circular perforations of the Layout BIM (5^th element of the layout).

Once the J-BIM (1st element in the BIM row) is properly locked to the layout layer then the two tails and pins formed by the side legs of the J-BIM are interlocked to the top tails and pins formed by the top legs of a BIM (2nd element of the first BIM row). The top tails and pins of the J-BIM are then interlocked to the top tails and pins of a b-BIM (3^rd element of the first BIM row) rotated 90 degrees, which in turn is interlocked by its side tails and pins to the side tails and pins of a F- BIM (4rd element of the first BIM row), which in turn is interlocked by its bottom tails and pins to the side tails and pins of a L-BIM (5^th element of the first BIM row) rotated 90 degrees.

The third layer of the double wythe corner (the second layer created with several of the BIM types) is built starting with a L-BIM (the 1^st element in the second BIM row) where the two pins located at the bottom of the two side legs of the L-BIM lock with two of the four circular perforations of the J-BIM (1st element of the first BIM row) right below and the two pins located at the bottom of the two top legs of the L-BIM lock with two of the four circular perforations of the BIM right below (2nd element of the first BIM row).

Once the L-BIM (the 1^st element in the second BIM row) is properly locked to the row right below then the two tails and pins formed by the side legs of the L-BIM are interlocked to the bottom tails and pins formed by the bottom legs of a BIM (2nd element of the second BIM row). The top tails and pins of the L-BIM are then interlocked to the bottom tails and pins of a F-BIM (3^rd element of the second BIM row), which in turn is interlocked by its side tails and pins to the side tails and pins of a b-BIM (4^th element of the second BIM row) rotated 90 degrees, which in turn is interlocked by its top tails and pins to the side tails and pins of a J-BIM (5^th element of the second BIM row).

All subsequent layers of the Double Wythe Corner are created repeating the steps detailed to create the second and third layer of the Double Wythe Corner.

Column attached to a single or several ( no more than four) Double Wythe Wa!l/walis

73. A Column attached to a single or several (no more than four) double wythe wall/walls formed of:

One or several (up to four) distinct two wythes wall formed of multiple layers which in turn are formed by a plurality of inter-fitting/inter-locking b-BIMs (as set forth in claims from 17 thru 19) and F-BIMs (as set forth in claims from 30 thru 32) and a single layout layer formed by a plurality of Layout b-BIMs (of as set forth in claims from 49 thru 20) and Layout F-BIMs (of as set forth in claims from 55 thru 56).

And

A single wythe column formed of multiple layers which in turn are formed by a plurality of inter- fitting/inter-locking BIMs (as set forth in claims from 1 thru 9), J-BIMs (as set forth in claims from 39 thru 41) and L-BIM (as set forth in claims from 42 thru 44) as well as a single layout layer formed by a plurality of Layout BIMs (of as set forth in claims from 10 thru 16), Layout J-BIMs (of as set forth in claims from 61 thru 62) and Layout L-BIMs (of as set forth in claims from 63 thru 64). wherein: each two wythes wall (up to four) is attached to the single wythe column.

74. A method of forming a generally vertical column attached to a single or several (no more than four) double wythe wall/walls wherein:

The first layer of the column attached to a single or several (no more than four) double wythe wall/walls is the layout layer and it is built starting with a Layout L-BIM (1^st element in the layout) interlocked by its top tails and pins with the bottom tails and pins of a Layout BIM (2^nd element in the layout), which in turn is interlocked by its top tails and pins with the top tail and pins of a Layout J-BIM (3^rd element in the layout), which in turn is interlocked by its side tails and pins to the top tails and pins of a Layout L-BIM (4^th element in the layout), which in turn is interlocked by its side tails and pins toe= the bottom tails and pins of a Layout F-BIM (5^th element in the layout), which in turn is interlocked by its side tails and pins to the side tails and pins of a Layout b-BIM (6^th element in the layout) rotated 180 degrees, which in turn is interlocked by its top tails and pins to the side tails and pins of a Layout J-BIM (7^th element in the layout) rotated 90 degrees, which in turn is interlocked by its top tails and pins to the side tails and pins of a Layout L-BIM (8^th element in the layout) rotated 180 degrees, which in turn is interlocked by its top tail and pins to the side tails and pins of a Layout J-BIM (9^th element of the layout), which in turn is interlocked by its top tails and pins to the bottom tails and pins of a Layout F-BIM (10^th element of the layout), which in turn is interlocked by its side tails and pins to the side tails and pins of a Layout b-BIM (11^th element of the layout) rotated 180 degrees, which in turn is interlocked by its top tails and pins to the top tails and pins of a Layout L-BIM (12^th element of the layout),which in turn is interlocked by its side tails and pins to the top tails and pins of a Layout J-BIM (13^th element of the layout), which in turn is interlocked by its side tails and pints to the bottom tails and pins of a Layout BIM (14^th element of the layout), which in turn is interlocked by its top tails an pins to the bottom tails and pins of yet another Layout BIM (15^th element in the layout), which in turn is interlocked by its top tails and pins to the side tails and pins of the first element in the layout (Layout L-BIM).

The second layer (the first layer created with several of the BIM types) is built starting with a J- BIM (1st element of the first BIM row) where the two pins located at the bottom of the two side legs of the J-BIM lock with two of the four circular perforations of the Layout L-BIM (1st element in the layout) right below and the two pins located at the bottom of the two top legs of the J-BIM lock with two of the four circular perforations of the Layout BIM (10th element in the layout).

Once the Layout J-BIM (1^st element in the row) is properly locked to the layout layer then the two tails and pins formed by the side legs of the J-BIM are interlocked to the top tails and pins formed by the top legs of a BIM (2^nd element of the first row), which in turn is interlocked by bottom tails an pins to the top tails and pins of a BIM (3^rd element in the row), which in turn is interlocked by its bottom tails and pins to the side tails and pins of a L-BIM (4^th element in the row), which in turn is interlocked by its top tails and pins to the side tails and pins of a J-BIM (5^th element of the row). At this point it is required to extend the layout layer that is located right under the 5^th element of the row, with a set formed by adding one Layout F-BIM interlocked by its side tails and pins to a Layout b-BIM rotated 180 degrees, this set is added to the end of the layout layer. Then the 5^th element of the row (J-BIM) is interlocked by its top tails and pins to the bottom tails and pins of a F-BIM (6^th element of the row), which in turn is interlocked by its side tails and pins to the side tails and pins of a b-BIM (7^th element in the row) rotates 180 degrees, which in turn is interlocked by its top tails and pins to a L-BIM (8^th element of the row), which in turn is interlocked by its side tails and pins to the top tails and pins of a J-BIM (9^th element of the row), which in turn is interlocked by its side tails and pins to the top tails and pins of a L-BIM (10^th element of the row), which in turn is interlocked by its side tails and pins to the bottom tails and pins of a F-BIM (11^th element of the row), which in turn is interlocked by its side tails and pins to the side tails an pins of a b-BIM (12^th element of the row) rotated 180 degrees, which in turn is interlocked by its to tails and pins to the side tails and pins of a J-BIM (13^th element of the row), which in turn is interlocked by its top tails and pins to the side tails and pins of a L-BIM (14^th element of the row), which in turn is interlocked by its top tails and pins to the bottom tails and pins of a BIM (15^th element of the row), which in turn is interlocked by its top tails and pins to the top tails and pins of the 1^st element of the row (the J-BIM). The third layer (the second layer created with several of the BIM types) is built starting with a L- BIM (1st element of the second row) where the two pins located at the bottom of the two side legs of the L-BIM locks with two of the four circular perforations of the Layout J-BIM (1st element in the first row) right below and the two pins located at the bottom of the two top legs of the L- BIM lock with two of the four circular perforations of the Layout BIM (2^nd element in the first row).

Once the Layout L-BIM (1^st element in the second row) is properly locked to the row right below then the two tails and pins formed by the top legs of the L-BIM are interlocked to the top tails and pins of a BIM (2^nd element in the second row), which in turn is interlocked by its bottom tails and pins to the top tails and pins of a J-BIM (3^rd element in the second row), which in turn is interlocked by its side tails and pins to the top tails and pins of a L-BIM (4^th element in the second row), which in turn is interlocked by its side tails and pins to the bottom tails and pins of a F-BIM (5^th element in the second row), which in turn is interlocked by its side tails and pins to the side tails and pins of a b-BIM (6^th element in the second row) rotated 180 degrees, which in turn is interlocked by its top tails and pins to the side tails and pins of a J-BIM (7^th element in the second row), which in turn is interlocked by its top tails and pins to the side tails and pins of a L-BIM (8^th element in the second row), which in turn is interlocked by its top tails and pins to the side tails and pins of a J- BIM (9^th element second row)

At this point the layout layer under the 9^th element must be extended by adding a Layout F-BIM interlocked by its side tails and pins to the side tails and pins of a Layout b-BIM rotated 180 degrees. The set formed by the Layout F-BIM and the Layout b-BI M should be added to the end of the layout layer. Also the first row must be extended by adding a F-BIM interlocked by its side tails and pins to the side tails and pins of a b-BIM rotated 180 degrees. The set formed by the F- BIM and the b-BIM should be added to the end the first row.

Then the 9^th element in the second row (J-BIM) is interlocked by its top tails and pins to the bottom tails and pins of a F-BIM (10^th element in the second row), which in turn is interlocked by its side tails and pins to the side tails and pins of a b-BIM (11^th element in the second row) rotated 180 degrees, which in turn is interlocked by its top tails and pins to the top tails and pins of a L-BIM (12^th element in the second row), which in turn is interlocked by its side tails and pins to the top tails and pins of a J-BIM (13^th element in the row), which in turn is interlocked by its side tails and pins to the bottom tails and pins of a BIM (14^th element in the second row), which in turn is interlocked by its top tails and pins to the bottom tails and pins of a BIM (15^th element in the second row), which in turn is interlocked by its top tails and pins to the side tails and pins of the 1^st element in the second row (L-BIM). All subsequent layers of the column attached to a single or several Double Wythe Wall/walls are created repeating the steps detailed to create the second and third layer of the column attached to a single or several Double Wythe Wall/walls.

-Shape intercepti ng Double Wythe WaNs

75. T-Shape intercepting double wythe walls formed of multiple layers which in turn are formed by a plurality of inter-fitting/inter-locking BIMs (as set forth in claims from 1 thru 9), L-BIM (as set forth in claims from 42 thru 44), b-BIMS, F-BIMS and J-BIMs (as set forth in claims from 39 thru 41), as well as a single layout layer formed by a Layout BIMs (of as set forth in claims from 10 thru 16), a Layout L-BIM, a Layout b-BIM, a Layout F-BIM and a Layout J-BIMs (of as set forth in claims from 61 thru 62).

76. A method of forming a generally vertical T-Shape intercepting double wythe walls wherein:

The first layer of the T-Shape intercepting double wythe walls is the layout layer and it is built starting with a Layout F-BIM (1st element in the layout) interlocked by its top tails and pins with the bottom tails and pins of a Layout BIM (2nd element in the layout), which in turn is interlocked by its top tails and pins to the bottom tails and pins of a Layout F-BIM (3^rd element of the layout), which in turn is interlocked by its side tails and pins to the side tails and pins of a Layout b-BIM (4^th element in the layout) rotated 180 degrees, which in turn is interlocked by its top tails and pins to the side tails and pins of a Layout J-BIM (5^th element in the layout), which in turn is interlocked by its top tails and pins to the bottom tails and pins of a Layout F-BIM (6^th element in the layout), which in turn is interlocked by its side tail and pins to the side tails and pins of a Layout b-BIM (7^th element in the layout), which in turn is interlocked by its top tail and pins to the top tails and pins of a Layout L-BIM (8^th element in the layout), which in turn is interlocked by its side tails and pins to the bottom tails and pins of a Layout b-BIM (9^th element in the layout), which in turn is interlocked by its side tails and pins to the side tails and pins of the 1^st element in the layout (the Layout F-BIM).

The second layer (the first layer created with several of the BIM types) is built starting with a BIM (1st element of the first BIM row) where the two pins located at the bottom of the two top legs of the BIM lock with two of the four circular perforations of the Layout F-BIM (1^st element in the layout) right below and the two pins located at the bottom of the two bottom legs of the BIM lock with two of the four circular perforations of the Layout BIM (2^nd element of the layout).

Once the BIM (1^st element in the first row) is properly locked to the layout layer then the two tails and pins formed by the bottom legs of the BIM are interlocked to the top tails and pins formed by the top legs of a BIM (2^nd element of the first row).

The 3^rd element in the first BIM row (a L-BIM) is set where the two pins located at the bottom of the two top legs of the L-BIM lock with two of the four circular perforations of the Layout b-BIM (4^th element in the layout layer) and the two pins located at the bottom of the two side legs lock with two of the four circular perforations of the 5^th element in the layout layer (a Layout J-BIM). The 3^rd element is also interlocked by its side tails and pins to the bottom tails and pins of a BIM (the 4^th element of the first row).

The 5^th element of the row (a BIM) is set where the two pins located at the bottom of the two top legs of the BIM lock with two of the four circular perforations of the Layout b-BIM (the 7^th element of the layout row) and the two pins located at the bottom of the two bottom legs lock with two of the four circular perforations of the 8^th element of the layout row (L-BIM). The 5^th element is also interlocked by its bottom tails and pins to the side tails and pins of a J-BIM (the 6^th element in the first row).

The third layer of the T-Shape intercepting Double Wythe Walls (the second layer created with several of the BIM types) is built starting with a BIM (the 1st element in the second row) where the two pins located at the bottom of the two top legs of the BIM lock with two of the four circular perforations of the BIM (1st element of the first BIM row) right below and the two pins located at the bottom of the two bottom legs of the BIM lock with two of the four circular perforations of the BIM right below (2nd element of the first BIM row).

The 2^nd element in the second row (a J-BIM) is set where the two pins located at the bottom of the two side legs lock with two of the four circular perforations of the 3^rd element in the first row (a L-BIM) and the two pins located at the bottom of the two tops legs lock with two of the four circular perforations of the 4^th element in the first row (a BIM).

The 3^rd element in the second row (a L-BIM) is set where the two pins located at the bottom of the two top legs lock with two of the four circular perforations of the 5^th element in the first row (a BIM) and the two pins located at the bottom of the two side legs lock with two of the four circular perforations of the 6^th element in the first row (a J-BIM).

All subsequent layers of the T-Shape intercepting Double Wythe Walls are created repeating the steps detailed to create the second and third layer of the T-Shape intercepting Double Wythe Walls.

Windows opening for Double Wythe Walls

77. A windows opening for Double Wythe Walls formed of multiple layers which in turn are formed by a plurality of inter-fitting/inter-locking X-BIMs (as set forth in claims from 45 thru 48) placed as the bottom side of the opening, L-BIMs (as set forth in claims from 42 thru 44) and J-BIMs (as set forth in claims from 39 thru 41) placed as one of the layers that forms both sides of the windows opening combined with yet another layer that forms both sides of the windows opening made of C-BIMs (as set forth in claims from 20 thru 24) and finally a single layout layer placed at the top side of the windows opening formed by a plurality of Layout b-BIMs (of as set forth in claims from 49 thru 20) and Layout F-BIMs (of as set forth in claims from 55 thru 56).

78. A method of forming a rectangular windows opening for Double Wythe Wall wherein: The first layer of the windows opening (the bottom side of the opening) is built utilizing a plurality of sets formed by a X-BIM interlocked to yet another X-BIM rotated 180 degrees.

At the end of each side of the bottom opening the set interlocks with the end of a Double Wythe Wall made with a plurality of b-BIMs (as set forth in claims from 17 thru 19) and F-BIMs (as set forth in claims from 30 thru 32).

The second layer of the windows opening (the left and right sides of the opening) is built utilizing a plurality of C-BIMs where the four tails and pins of the C-BIMs interlock with the end of a Double Wythe Wall made with a plurality of b-BIMs (as set forth in claims from 17 thru 19) and F-BIMs (as set forth in claims from 30 thru 32).

The third layer of the windows opening (the left and right side of the opening) is built utilizing a plurality of L-BIMs and J-BIMs sets wherein each set is created by interlocking the side tails and pins of the L-BIMs with the side tails and pins of the L-BIMs. The top tails and pins of the L-BIM plus J-BIM set interlock with the end of a Double Wythe Wall made with a plurality of b-BIMs (as set forth in claims from 17 thru 19) and F-BIMs (as set forth in claims from 30 thru 32).

All subsequent windows opening layers forming the left and right side of the opening are formed by using the BIM types and repeating the steps described to create the second and third layer of the windows opening until the desired height of the opening is reached.

The final layer of the windows opening (the top side of the rectangular opening) is built utilizing a plurality of Layout b-BIMs and Layout F-BIMs sets wherein each layout set is created by rotating the Layout b-BIM 180 degrees and interlocking its side tails and pins with the side tails and pins of the Layout F-BIM.

A plurality of Lintel-BIMs and Lintel-End-BIMs that spans the space or opening between two vertical sides of the windows opening and interlocks with the ends of a Double Whyte Wall, may or may-not be utilized. In this case it not utilized since the actual structure of the window (formed utilizing aluminum windows frames and single pane glass or double pane glass) would be designed to support the load of BIM layers that are placed right on top of the windows opening. Door opening for Double Wythe Walls

79. A door opening for Double Wythe Walls formed of multiple layers which in turn are formed by L- BIMs (as set forth in claims from 42 thru 44) and J-BIMs (as set forth in claims from 39 thru 41) placed as one of the layers that forms both sides of the door opening combined with yet another layer that forms both sides of the door opening made of C-BIMs (as set forth in claims from 20 thru 24) and finally a single layout layer placed at the top side of the door opening formed by a plurality of Layout b-BIMs (of as set forth in claims from 49 thru 20) and Layout F-BIMs (of as set forth in claims from 55 thru 56).

80. A method of forming a rectangular door opening for Double Wythe Wall wherein:

First layer of the door opening (the left and right sides of the opening) is built utilizing a plurality of C-BIMs where the four tails and pins of the C-BIMs interlock with the end of a Double Wythe Wall made with a plurality of b-BIMs (as set forth in claims from 17 thru 19) and F-BIMs (as set forth in claims from 30 thru 32).

Second layer of the door opening (the left and right side of the opening) is built utilizing a plurality of L-BIMs and J-BIMs sets wherein each set is created by interlocking the side tails and pins of the L-BIMs with the side tails and pins of the L-BIMs. The top tails and pins of the L-BIM plus J-BIM set interlock with the end of a Double Wythe Wall made with a plurality of b-BIMs (as set forth in claims from 17 thru 19) and F-BIMs (as set forth in claims from 30 thru 32).

All subsequent door opening layers forming the left and right side of the opening are formed by using the BIM types and repeating the steps described to create the first and second layer of the windows opening until the desired height of the opening is reached.

The final layer of the door opening (the top side of the rectangular opening) is built utilizing a plurality of Layout b-BIMs and Layout F-BIMs sets wherein each layout set is created by rotating the Layout b-BIM 180 degrees and interlocking its side tails and pins with the side tails and pins of the Layout F-BIM.

A plurality of Lintel-BIMs and Lintel-End-BIMs that spans the space or opening between two vertical sides of the door opening and interlocks with the ends of a Double Whyte Wall, may or may-not be utilized. In this case it is utilized since the actual structure of the door frame is not designed to support the load of BIM layers that are placed right on top of the door opening. Box-Bi

81. A modular building unit adapted for inter-fitting/inter-locking with adjacent building units; said modular building unit comprising:

A box block interlocking module (box-BIM) made of polymer including a pair of parallel rectangular end supporting faces, a pair of parallel rectangular side faces, and parallel rectangular upper and lower supporting faces, a pair of parallel rectangular faces extending vertically from each of the end faces, a pair of parallel rectangular faces extending vertically from one side, the right side, of the side face.

A cover plate for the box-BIM made of polymer including a pair of parallel rectangular end supporting faces, a pair of parallel rectangular side faces, and parallel rectangular upper and lower supporting faces.

82. The pair of parallel rectangular faces extending vertically from one side, the right side, of the side face as set forth in claim 81 has a perforation that allows the installation of any construction item that would fit inside the space created once the box plate is attached to the box. Uses for the box include a point of exit for plumbing pipes from a Single Whyte Wall or a Double Whyte Wall.

83. The top parallel planar surface extending over the entire upper face of the block set forth in claim 81 may have, depending on the model, two additional perforations located on each side of the four aligned circular perforations to save material during the production process. Each preformation goes from one side of the top planar surface to the other side of the planar surface. arc-B! M

84. An arc shaped modular building unit adapted for inter-fitting/inter-locking with adjacent

building units; said modular building unit comprising:

an arc shaped block formed of a homogenous material and including a pair of rectangular end supporting faces, a pair of parallel arc shaped side supporting faces, and parallel arc shaped upper and lower supporting faces; and

an arc shaped block interlocking module (arc-BIM) made of polymer including a pair of parallel end supporting faces, a pair of parallel arc shaped side faces, and parallel arc shaped upper and lower supporting faces.

85. The upper and lower supporting faces of the arc shaped block interlocking module (arc-BIM) set forth in claim 84 extends over the entire upper face of the block.

86. The top arch shaped planar surface set forth in claim 85 has four circular perforations located at the center of the arc-BIM. Each preformation goes from one side of the top planar surface to the other side of the planar surface.

87. The top parallel planar surface extending over the entire upper face of the block set forth in claim 85 may have, depending on the model, two additional perforations located on each side of the four circular perforations to save material during the production process. Each preformation goes from one side of the top planar surface to the other side of the planar surface.

88. The arc shaped block interlocking module (arc-BIM) set forth in claim 84 has two vertical legs attached to each side of the end supporting faces.

89. Each vertical leg set forth in claim 88 has a trapezoidal shape and is placed in a way that forms two dovetail-tails and two dovetail-sockets on each side of the end supporting faces of the arc- BIM.

90. The tails and sockets set forth in claim 89 create a pattern that allows adjacent building units to inter-lock for mounting of adjacent building units in precise horizontal layers with each horizontal layer including a plurality of building units in end to end.

91. Each vertical leg set forth in claim 89 ends in a cylindrical form that creates a pin that locks in one of the four circular perforations set forth in claim 86 of a BIM located in the horizontal layer right below.

92. The four aligned perforations set forth in claim 86 and the pins at the end of each leg set forth in claim 91 are designed in a way that the arc-BIMs lock permanently or lock properly (yet disassembling several horizontal layers is possible).

Layout arc-BI

93. An arc shaped layout block interlocking module (Layout arc-BIM) made of polymer including a pair of parallel end supporting faces, a pair of parallel arc shaped side faces, and parallel arc shaped upper and lower supporting faces.

94. The upper and lower supporting faces of the Layout arc-BIM set forth in claim 93 extends over the entire lower face of the block.

95. The parallel planar surface set forth in claim 93 has four aligned circular perforations located at the center of the Layout arc-BIM. Each preformation goes from one side of the top planar surface to the other side of the planar surface.

96. The top parallel planar surface extending over the entire upper face of the Layout arc-BIM set forth in claim 93 may have, depending on the model, two additional perforations located on each side of the four aligned circular perforations to save material during the production process.

97. The Layout arc-BIM set forth in claim 93 has two trapezoidal extensions attached to each side of the end supporting faces also set forth in claim 93.

98. Each extension set forth in claim 97 is placed in a way that forms two dovetail-tails and two dovetail-sockets on each side of the layout arc shaped block interlocking module.

99. The tails and sockets set forth in claim 98 create a pattern that allows adjacent layout units to inter-lock for mounting of adjacent layout units in a precise horizontal layer with the horizontal layer including a plurality of layout units in end to end.

L!ntel-B!

100. A modular building unit adapted for inter-fitting/inter-locking with adjacent building units; said modular building unit comprising: a block formed of a homogenous material and including a pair of parallel rectangular end supporting faces, a pair of parallel rectangular side supporting faces, and parallel rectangular upper and lower supporting faces (for example a 194 x 46 x 57 mm clay brick); and a lintel block interlocking module (Lintel-BIM) made of polymer including a pair of parallel rectangular end supporting faces, a pair of parallel rectangular side faces, and parallel rectangular upper and lower supporting faces.

101. The upper and lower supporting faces of the Lintel-BIM set forth in claim 100 extends over the entire upper face of the block.

102. The upper parallel planar surface set forth in claim 101 has eight aligned circular perforations located at the center of the Lintel-BIM. Each preformation goes from one side of the top planar surface to the other side of the planar surface.

103. The Lintel-BIM set forth in claim 100 has two vertical legs attached to each side of the end supporting faces.

104. Each vertical leg set forth in claim 103 has a trapezoidal shape and is placed in a way that forms two dovetail-tails and two dovetail-sockets on each side of the end supporting faces of the block interlocking module.

105. The tails and sockets set forth in claim 104 create a pattern that allows adjacent Lintel- BIM to inter-lock with another adjacent Lintel-BIM (or adjacent Lintel-End-BIM) in precise horizontal layers with each horizontal layer including a plurality of building units in end to end.

106. Each vertical leg set forth in claim 103 ends in a cylindrical form that creates a pin that locks in one of the eight aligned circular perforations set forth in claim 102 of a Lintel-BIM (or a BIM or a Layout-BIM) located in the horizontal layer right below.

107. The eight aligned perforations set forth in claim 102 and the pins at the end of each leg set forth in claim 106 are designed in a way that the Lintel-BIMs lock permanently or lock properly yet disassembling several horizontal layers is possible. Lintel End-B! M

108. A modular building unit adapted for inter-fitting/inter-locking with adjacent building units; said modular building unit comprising:

a block formed of a homogenous material and including a pair of parallel rectangular end supporting faces, a pair of parallel rectangular side supporting faces, and parallel rectangular upper and lower supporting faces (for example a 194 x 46 x 57 mm clay brick); and

a lintel end block interlocking module (Lintel End-BIM) made of polymer including a pair of parallel rectangular end supporting faces, a pair of parallel rectangular side faces, and parallel rectangular upper and lower supporting faces.

109. The upper and lower supporting faces of the Lintel End-BIM set forth in claim 108 extends over the entire upper face of the block.

110. The upper parallel planar surface set forth in claim 109 has eight aligned circular perforations located at the center of the Lintel End-BIM. Each preformation goes from one side of the top planar surface to the other side of the planar surface.

111. The Lintel End-BIM set forth in claim 108 has six vertical legs attached to each side of the end supporting faces.

112. Each vertical leg set forth in claim 111 has a trapezoidal shape and is placed in a way that forms two dovetail-tails and two dovetail-sockets on each side of the end supporting faces of the block interlocking module.

113. The tails and sockets set forth in claim 112 create a pattern that allows Lintel End-BIMs to inter-lock with another adjacent Lintel-BIM (or adjacent BIM) in precise horizontal layers with each horizontal layer including a plurality of building units in end to end.

114. Each vertical leg set forth in claim 111 ends in a cylindrical form that creates a pin that locks in one of the eight aligned circular perforations set forth in claim 110 of a Lintel End-BIM (or a Lintel-BIM or a BIM or a Layout-BIM) located in the horizontal layer right below.

115. The eight aligned perforations set forth in claim 110 and the pins at the end of each leg set forth in claim 111 are designed in a way that the Lintel End-BIMs lock permanently or lock properly yet disassembling several horizontal layers is possible. gle Wythe Arc Sha ed Wail

116. A Single Wythe Arc shaped wall formed of multiple layers which in turn are formed by a plurality of inter-fitting/inter-locking arc-BIMs as set forth in claims from 84 thru 92 and a single layout layer formed by a plurality of Layout arc-BIMs of as set forth in claims from 93 thru 99.

117. A method of forming a generally vertical single wythe arc shaped wall wherein:

The first layer of the arc shaped wall is the layout layer built utilizing a plurality of Layout arc- BIMs. The first Layout arc-BIM of the layout layer is placed (or anchored) to the floor, then its bottom tails and pins are interlocked to the top tails and pins of the second Layout arc-BIM, which in turn is interlocked by its bottom tails and pins to the top tails and pins of yet another Layout arc-BIM. Every arc-BIM thereafter follows the same installation pattern forming a row of Layout arc-BIMs that can be extended for as much distance as necessary.

All subsequent wall layers are made of a plurality of arc-BIMs where:

the pins set forth in claim 91 lock in one of the four aligned circular perforations set forth in claim 86 (or 95 if Layout arc-BIM if the first arc-BIM layer) of an arc- BIM (or Layout arc-BIM if the first arc-BIM layer) located in the horizontal layer right below.

Each arc-BIM interlocks by its bottom tails and pins to the top tails and pins of the next arc-BIM down the row.

Description:

AIM IMPROVED SYSTEM TO BUILD BIM-BASED STRUCTURES LIKE THE WALLS AND COLUMNS OF A SINGLE FAMILY RESIDENTIAL HOME OR OTHER RESIDENTIAL AND COMMERCIAL BUILDINGS AS WELL AS FENCES, CIRCULAR AND SEMI-CIRCUALR STRUCTURES AND OTHER ARCHITECTURAL STRUCTURES.

A SYSTEM THAT INCLUDES LAYOUT UNITS, MODULAR BUILDING UNITS, THE METHODS TO MANUFACTURE SUCH AS WELL AS THE DETAILS TO BUILD SIMPLE STRUCTURES LIKE SINGLE AND DOUBLE WHYTE WALLS, SINGLE WHYTE ARC- SHAPED WALLS, SINGLE WHYTE COLUMNS, DOUBLE WHYTE WALL CORNERS, WINDOWS AND DOOR OPENINGS. THE SYSTEM ALSO INCLUDES BUILDING UNITS THAT FACILITATE THE INSTALLATION OF ELECTRICAL OUTLETS AND SWITCHES AS WELL AS OTHER CONSTRUCTION COMPONENTS. Description 2

BACKGROUND OF THE INVENTION 2

Field of the Invention 2

Description of the Prior Art 2

SUMMARY OF THE INVENTION 3

Summary 3

Fusing the BIM with the Bricks 8

Polymers 9

Field of the Invention

The present invention pertains to masonry construction. More specifically, the present invention pertains to an improved system to build structures like the walls and columns of a single family residential home or other residential and commercial buildings as well as fences, circular and semi-circular and other architectural structures. The present invention also pertains to building block units, installation of building block units and methods of manufacturing and utilizing such. In particular, the present invention pertains to a unique building block unit or modular building unit in which a standard brick or other type of building block is placed in a mold and a block interlocking module (BIM) that utilizes dovetail joints is applied to three of the faces of the brick or other type of building block and allowed to set as an additional manufacturing step to form a single building block unit.

Description of the Pr ior Art

Masonry construction, one of the traditional methods of building, has been utilized for many centuries. Masonry, simply stated, is the assembly of building block units, such as bricks, stone, concrete, etc., by laying such units adjacent to each other in a composite wall, column or other structure. These units are typically joined by some type of mortar which is wet and mixed and applied to the surface of one building unit or block adjacent thereto. The mortar sets up, cementing the building units together as it hardens. Such masonry construction has distinctive architectural characteristics which have been desired throughout the ages, still being the type of construction preferred by many.

Because of its strength, relative uniformity, appearance and other characteristics, the brick, and especially the fired clay brick, has been one of the most used and desired building units for masonry construction. The typical brick is in the shape of a rectangular box and in building a wall with bricks, layers of bricks are laid in stepped or staggered relationships so that an overlying brick straddles the joint of a pair of underlying bricks. While the typical rectangular box-like brick is most common, a number of brick and other building block shapes have been developed over the years to obtain enhanced appearances, more uniform construction, or other characteristics sought for masonry construction. Examples of such specially designed bricks or building blocks may be seen in U.S. Pat. Nos. 3,299,599; 3,479,782; 3,936,987; 4,091,587; 4,124,961 and 5,715,635. In fact, there are countless shapes and designs in bricks and other building blocks.

The typical kiln fired bricks utilized in masonry construction are made of clay or shale. The bricks are typically molded, dried and burned in kilns. There are several methods of molding bricks and other building blocks. There are several qualities of bricks and other building blocks, quality being determined by strength, durability, etc. One of the major problems associated with masonry construction is the non- uniformity of building block dimensions due to shrinkage, warping, twisting, etc. Because of these characteristics, mortar is necessary not only to bond the bricks or other building blocks together, but to smooth out the irregularities thereof.

Another major problem associated with masonry construction is the mortar materials utilized to bond the bricks or other building blocks together. In many respects, mortar is the weak link in masonry construction. It normally has less compressive and tensile strength than the building blocks it joins. The shear strength of masonry is a function of the bond strength of mortar to the associated brick or other building block and frictional resistance at the building block-mortar interface. The water tightness of masonry construction is primarily dictated by the characteristics of the mortar which is more water permeable than brick and most other building block materials. While so much depends on the quality of mortar used, mortars are typically mixed at the job site and can easily be incorrectly mixed or used beyond its useful mix life. Thus, even though masonry construction has been utilized for centuries, there are still some inherent problems pertaining to the lack of uniformity of quality and dimensions in the brick or other building blocks and to the weaknesses associated with the mortars used therewith. Accordingly, the search continues for improved masonry construction.

The prior art is generally directed to building units which have blocks in a flush relation to each other and do not include a separate block interlocking module extending about the periphery of a block for separating adjacent blocks from each other. U.S. Pat. No. 2,077,750 dated Apr. 20, 1937 shows a mounting border along opposed sides of a building block but not a block interlocking module. U.S. Pat. No. 4,426,815 dated Jan. 24, 1984 likewise does not show a separate block interlocking module secured about the periphery of a block and adjacent blocks are in flush relation to each other, not separated by a block interlocking module or the like.

Summery

The primary objects of the present invention are:

a- To provide an improved system to build structures like the walls and columns of a single family residential home or other residential and commercial buildings as well as fences, circular and semi-circular structures and other architectural structures

b- To provide a unique dimensionally accurate building block unit and method of manufacturing such.

The term "building block unit" or "modular building unit" as used herein refers to a brick or other building block in combination with a separate block interlocking module (BIM) preferably formed of Polymer which together form a manufactured building block unit (or a BIM- eady manufactured building block unit) for delivery to a building site. Figure 1 below shows a BIM-Ready manufactured building block unit.

Fusing the B! with the Bricks

The first step in the manufacturing process is to perform two parallel trapezoidal cuts along the upper planar rectangular face as set forth in claim 1. The length of each cut will never exceed the total length of the upper planar fade thus keeping the pair of parallel rectangular side supporting faces as set forth in claim 1 without any visible cuts. This is important as it will keep the aesthetics of walls and other structures built utilizing the present invention. Please see Figures 55, 56, 57 and 58 for details.

Now with the two trapezoidal cuts along the upper face the brick is placed in a dimensionally accurate mold. The brick may be generally centered in the mold and held in this disposition in any number of known ways, such as a force applied against the pair of parallel rectangular side supporting faces as set forth in claim 1. It is, of course, noted that voids surround the end faces and upper face of the brick. No void or space is provided to the side faces or the lower supporting face as set forth in claim 1.

Injection molding is among the most commonly used manufacturing process for the fabrication of plastic parts. The injection molding process is basically based on the molten die-casting method. The injection- molding unit consists of two elements: the injection unit, and the mold. Unlike extrusion, injection molding forms three-dimensional shapes making this process ideal to cast the block interlocking modules of the present invention.

With the brick in place and the mold closed a flowing polymer mix is injected into the voids surrounding end faces and upper face of the brick through suitable openings in the mold. After dispensing of the polymer within openings the openings will be plugged.

At this stage the polymer is allowed to set. The outside surfaces of the resulting unit conform to the dimensionally accurate inside surfaces of the mold. After the polymer has cured and hardened, it is described as being "pre-applied", "preset" or "fused".

Human inspectors check the output of the molds, to eliminate significant variations in thickness.

BIMs factories should be able to recycle almost all the plastic waste from the manufacturing process. If the plastic cannot be re-used in BIMs, it should be processed and sold on to industries that can make use of it.

The pre-application and presetting of a polymer on each building block (prior to installation) assures a dimensionally accurate composite building block and when interlocked to adjacent building block units results in a predetermined dimensionally accurate construction. Not only is the final construction dimensionally accurate, it is much stronger and has characteristics which are improved over the prior art, particularly in the mortar area. Due to the fact that the polymer is pre-applied and preset under conditions much more favorable than in field mixing operations, the polymer is stronger, less permeable to water, more uniform in appearance, and not susceptible to creep. The joint formed with the present invention is stable and strong and substantially eliminates water infiltration. It also eliminates the need for "striking" or "working" the mortar in the usual masonry sense.

Regardless of which polymer materials are selected and even if the building blocks to which they are applied are non-uniform, it can be understood that the polymer, by being pre-applied in a dimensionally accurate mold within specified tolerances, will result in extremely accurate outside to outside dimensions so that inter-fitting/inter-locking BIMs will be in a predetermined dimensionally accurate relationship.

Polymers

ABS (acrylonitrile butadiene styrene) is a common thermoplastic polymer. The most important mechanical properties of ABS are impact resistance and toughness. A variety of modifications can be made to improve impact resistance, toughness, and heat resistance of this polymer therefore it can be considered a satisfactory polymer material for manufacturing BIMs and arc-BIMs.

During the process the ABS plastic is heated to 232 °C (450 °F) until it reaches a dough-like consistency. It is then injected into the molds at pressures between 25 and 150 ton. ABS takes approximately 15 seconds to cool. The mold are permitted a tolerance of up to two micrometers, to ensure the BIMs remain connected.

Other polymers may also be considered suitable to manufacture BIMs and arc-BIMs. A large variety of plastic materials are often used for outdoor applications such as architectural glazing, mass transportation interiors, and marine dock fenders. Certain plastics such as acrylic, Ultem, PVDF, and PTFE are inherently UV stable. However, most plastic materials exhibit color change and loss of elongation when exposed to UV light. Weathering resistance of some plastics can be improved by adding UV stabilizers or UV resistant caps to protect the base polymer.

Acrylic is a transparent thermoplastic material with outstanding strength, stiffness, and optical clarity. Acrylic sheet is easy to fabricate, bonds well with adhesives and solvents, and is easy to thermoform. It has superior weathering properties compared to many other transparent plastics. Acrylic sheet exhibits glass-like qualities— clarity, brilliance, and transparency— but at half the weight and many times the impact resistance of glass. From durable signs and skylights, to eye-catching retail store fixtures, displays and shelves, acrylic provides outstanding versatility, durability, and aesthetic qualities.

Regardless of which polymer materials is selected it can be understood that the polymer will have the versatility, durability, and aesthetic qualities required.

Some fire-safe polymers naturally exhibit an intrinsic resistance to decomposition, while others are synthesized by incorporating fire-resistant additives and fillers. The present invention does not provide details as of what kind of fire-resistant additives and fillers can be utilized to form the block interlocking modules; however it is understood that this topic will be considered as part of the research process that goes before selecting the polymer(s) utilized to manufacture the BIMs.

BRIEF DESCRIPTION OF THE DRAWINGS 2

Joints and Joint Profile and images 2

BIM Types images 6

Layout BIM Types images 11

Single Wythe Wall images 15

Double Wythe Wall images 16

Column Images 17

Double Wythe Wall Corner Images 18

Column attached to a single or several Double Wythe Wall/Walls images 19

Windows opening for Double Wythe Wall images 21

Door opening for Double Wythe Wall images 23

Other BIM models images 26

Single Wythe Arc Shaped Wall images 31

Fusing the BIMs and arc-BIMs with the bricks images 32

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION 34

194 x 92 x 57 mm clay brick dimensions 34

BIM dimensions 35

C-BIM Dimensions 37 e-BIM Dimensions 37

J-BIM Dimensions 38

Box-BIM Dimensions 39 arc-BIM Dimensions 40 arc Clay Brick Dimensions 40

Lintel-BIM Dimensions 41

Lintel End-BIM Dimensions 41

194 x 47.50 x 57 mm clay brick dimensions 42

6U l-shaped Steel Bar Dimensions 42

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