Modular wall assembly apparatus and method

Abstract

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

1 . A modular wall assembly having a structural system of cooperating building components comprising: 
 a plurality of premolded block units disposed end-to-end in a plurality of stacked, interlocking courses to form a configurable plurality of horizontal and vertical passageways for receiving material;    configurable, interlocking components to vertically align adjacent courses of said premolded block units, to longitudinally interlock said premolded block units within a course, and to configure selected horizontal passageways for receiving material; and    passage configuration components to configure selected vertical passageways for receiving material, a particular passage being configured to be open for receiving material, fully closed to receiving material, or partially closed to receiving a selected first material and partially open for receiving a selected second material, thereby providing improved control of selected material quantity and configuration.    
   
   
       2 . A method of constructing a structural system of cooperating building components having a plurality of premolded, interlocking block units, said method comprising the steps of: 
 assembling a plurality of premolded block units disposed end-to-end in a plurality of stacked, interlocking courses to form a configurable plurality of horizontal and vertical passageways for receiving material;    selectively configuring said plurality of horizontal and vertical passageways for receiving material using configuration components such that a particular passage is configured to be open for receiving material, fully closed to receiving material, or both partially closed to receiving a selected first material and partially open for receiving a selected second material, thereby selectively controlling both selected material quantity and configuration; and    introducing at least one of said materials into said selectively configured plurality of horizontal and vertical passages.    
   
   
       3 . A modular wall assembly having a structural system of cooperating building components comprising: 
 (a) a standard block;    (b) a corner block;    (c) an angular corner block;    (d) an adapter block,;    (e) a junction block;    (f) a terminal block;    (g) vertical, lateral, and longitudinal interlocking components;    (h) structural configuration components; and    (i) utility network alignment components;    said system of block units, interlocking components, structural configuration components, and utility network alignment components cooperating with one another to produce improved modular layout configurations for complete wall assemblies.    
   
   
       4 . The system of block units of  claim 1 , wherein said interlocking components overlap the vertical and longitudinal planes of adjoining modular block units to form at least one vertical and at least one longitudinal projection and a corresponding vertical and longitudinal recess, said projection and corresponding recess having a size and shape ensuring insertion and interlocking, thereby providing an uninterrupted sound, wind, thermal, and moisture barrier at all joints between said adjoining modular block units and said interlocking components further providing a particular vertical and longitudinal block orientation.  
   
   
       5 . The modular wall assembly system of  claim 1 , wherein said plurality of premolded block units includes a standard modular block unit and said interlocking components include vertical alignment components between courses to provide longitudinal dimensional integrity, thereby ensuring vertical alignment for structural configuration components and utility network alignment components.  
   
   
       6 . The vertical alignment components of  claim 1 , wherein said interlocking components and said configuration components include vertical alignment components, said vertical alignment components further including premolded interlocking projection and recess components integral to said modular block units.  
   
   
       7 . The modular wall assembly system of  claim 1 , wherein said plurality of premolded block units includes structural configuration components that have at least one vertical passage extending through said premolded block units for alternatively encapsulating reinforced cementitious material, encapsulating utility network components, or encapsulating entrained, insulating air.  
   
   
       8 . The system of block units of  claim 1 , wherein said system of block units is adapted to provide a configurable, recessed cavity for horizontally encapsulating any configuration of structural components and utility network alignment components, including the horizontal flow of fluid cement pumped or poured inside a modular wall assembly.  
   
   
       9 . The system of block units of  claim 1 , wherein said system of block units includes structural configuration components that have a vertical passage closure component and premolded recess components, whereby said premolded recess components are integral to said standard modular block unit, thereby providing structural configuration components to selectively configure encapsulated vertical passageways for receiving reinforced cementitious material.  
   
   
       10 . The modular wall assembly system of  claim 1 , wherein said system of block units includes utility network alignment components that have a configurable, vertical passage alignment component and premolded recess components, whereby said premolded recess components are integral to said standard modular block unit, thereby preventing obstruction of said vertical passage for said utility network.  
   
   
       11 . The modular wall assembly system of  claim 1 , wherein said system of block units includes symmetrical first and second corner block units for joining horizontally adjacent block units disposed perpendicularly, said first and second corner block units having opposing longitudinal block orientations, whereby said first and second corner block units allow adjacent block courses to traverse alternating longitudinal directions, thereby laterally offsetting vertical joints between adjacent block courses and improving layout configurability of said modular wall assembly.  
   
   
       12 . The modular wall assembly system of  claim 1 , wherein said system of block units includes symmetrical first and second angular corner block units for joining horizontally adjacent block units disposed to one another at an acute angle other than perpendicular, said first and second angular corner block units having opposing longitudinal block orientations, whereby said first and second angular corner block units allow adjacent block courses to traverse alternating longitudinal directions, thereby laterally offsetting vertical joints between adjacent block courses and improving layout configurability of said modular wall assembly.  
   
   
       13 . The modular wall assembly system of  claim 1 , wherein said system of block units includes an adapter block unit having identical longitudinal block orientations, wherein longitudinally adjacent blocks having opposing longitudinal directions are joined, thereby improving layout configurability of said modular wall assembly.  
   
   
       14 . The modular wall assembly system of  claim 1 , wherein said system of block units includes symmetrical first and second junction block units for joining horizontally adjacent block units disposed perpendicularly, said first and second junction block units having opposing longitudinal block orientations, whereby said first and second junction block units allow adjacent block courses to traverse alternating longitudinal directions, thereby laterally offsetting vertical joints between adjacent block courses and improving layout configurability of said modular wall assembly.  
   
   
       15 . The modular wall assembly system of  claim 1 , wherein said system of block units includes a terminal block unit having a single longitudinal block orientation, wherein a longitudinally adjacent block course is joined and terminated, thereby improving layout configurability of said modular wall assembly.  
   
   
       16 . The system of block units of  claim 1 , wherein said system of block units includes at least one block component face corresponding to a wall surface, said block component face being premolded with at least one vertical groove formed parallel to the center line of an encapsulated vertical passageway for receiving material, thereby providing means for designating a line of attachment to a structural component encapsulated in said vertical passageway.  
   
   
       17 . The modular wall assembly system of  claim 1 , wherein said modular wall assembly system includes a system of modular block units wherein at least one of its courses has modular block units made from a material selected from the group consisting of cement, fiber-reinforced cement, wood, stone, ceramic, metal, gypsum, and plastic.  
   
   
       18 . The modular wall assembly system of  claim 1 , wherein said modular wall assembly system includes a system of modular block units wherein at least one of its above grade courses has modular block units molded from a lightweight insulating material.  
   
   
       19 . The modular wall assembly system of  claim 1 , wherein said modular wall assembly system includes a system of modular block units wherein at least one of its below grade courses has modular block units molded from a material having structural properties suitable for resisting lateral forces due to hydrostatic pressure.