Modular block wall system

Abstract

A modular masonry system includes a plurality of masonry modules each having inner and outer structural members. Top and bottom spanning members extend the length of the inner and outer structural members and are retained within respective upper and lower retaining grooves of the inner and outer structural members. The top spanning member includes a second retaining feature that cooperates with a first retaining feature of the bottom spanning member of an adjacent masonry module. An insulation member is disposed within an interior volume defined between the inner and outer structural members and the top and bottom spanning members. The first retaining feature of each bottom spanning member slidably engages the second retaining feature of at least one vertically adjacent top spanning member. The engagement of the first and second retaining features aligns and secures the engaged masonry modules without the use of mortar.

What is claimed is: 
     
         1 . A block module for a modular block system, each block module comprising:
 a structural component having inner and outer portions; and   first and second retaining features extending outward from the inner and outer portions of the structural component, the first retaining feature being integrally formed with a first spanning member extending between the inner and outer portions of the structural component, and the second retaining feature being integrally formed with a second spanning member that opposes the first spanning member and extends between the inner and outer portions of the structural component, wherein the first and second spanning members position the inner and outer portions of the structural component at a predetermined spacing, wherein the first retaining feature is configured to slidably engage the second retaining feature of an adjacent block module.   
     
     
         2 . The block module of  claim 1 , wherein the first and second retaining features are mortar-free retaining features. 
     
     
         3 . The block module of  claim 1 , wherein the inner and outer portions of the structural component are defined by separate inner and outer structural components. 
     
     
         4 . The block module of  claim 1 , wherein an insulation member is engaged with the structural component. 
     
     
         5 . The block module of  claim 4 , wherein the insulation member is disposed between the inner and outer portions of the structural component. 
     
     
         6 . The block module of  claim 5 , wherein the first and second spanning members exert a laterally inward compressive force against the inner and outer portions of the structural component to compress the insulation member between the inner and outer portions and secure the inner and outer portions, the first and second spanning members and the insulation member in a unitary member to form the block module. 
     
     
         7 . The block module of  claim 1 , wherein the structural component is masonry. 
     
     
         8 . A block module for a modular block system, each block module comprising:
 a structural member having upper and lower retaining grooves;   a bottom spanning member extending a length of the structural member, wherein the bottom spanning member is configured to be retained within the lower retaining groove of the structural member, and wherein the bottom spanning member includes a first retaining feature;   a top spanning member extending the length of the structural member, the top spanning member retained within an upper retaining groove of the structural member, wherein the top spanning member includes a second retaining feature that is configured to matingly and slidably cooperate with the first retaining feature of an adjacent block module to vertically and laterally align the structural member with the adjacent block module; and   an insulation member disposed within an interior volume defined between the structural member and the top and bottom spanning members to define a unitary member.   
     
     
         9 . The block module of  claim 8 , wherein the structural member includes inner and outer structural members, the top and bottom spanning members extending between the upper and lower retaining grooves defined within each of the inner and outer structural members. 
     
     
         10 . The block module of  claim 9 , wherein the insulation member is disposed between the inner and outer structural members and the top and bottom spanning members. 
     
     
         11 . The block module of  claim 9 , wherein the top and bottom spanning members are adapted to position the inner and outer structural members at a predetermined distance. 
     
     
         12 . The block module of  claim 9 , wherein the top and bottom spanning members engage the upper and lower retaining grooves to exert a compressive force against the inner and outer structural members to compress the insulation member between the inner and outer structural members and secure the inner and outer structural members, the top and bottom spanning members and the insulation member in the unitary member. 
     
     
         13 . The block module of  claim 8 , wherein the insulation member is a solid piece of insulation. 
     
     
         14 . The block module of  claim 8 , wherein the inner and outer structural members are masonry. 
     
     
         15 . The block module of  claim 8 , wherein the top and bottom spanning members are made of plastic. 
     
     
         16 . A modular block system comprising:
 a plurality of block modules, each of the plurality of block modules including:
 a bottom spanning panel including engagement rails defined respectively within bottom opposing edges of the bottom spanning panel; 
 a top spanning panel having top opposing edges; and 
 an insulation member disposed within an interior volume defined between the top and bottom spanning panels, wherein the engagement rails of a first block module of the plurality of block modules is adapted to slidably engage the top opposing edges of the top spanning panel of at least one vertically adjacent block module of the plurality of block modules, wherein slidable engagement between the first block module and the at least one vertically adjacent block module secures and vertically and laterally aligns the first block module and the at least one vertically adjacent block module substantially free of the use of mortar, and wherein the first block module is unable to slidably engage two block modules of the at least one vertically adjacent block module when the two block modules are free of at least one of vertical and lateral alignment. 
   
     
     
         17 . The modular block system of  claim 16 , wherein each block module of the plurality of block modules includes at least one structural member, the top and bottom spanning panels extending from upper and lower retaining grooves, respectively, of the at least one structural member, wherein the at least one structural member and the top and bottom spanning panels cooperate to define the interior volume. 
     
     
         18 . The modular block system of  claim 17 , wherein the at least one structural member includes inner and outer structural members, wherein the top and bottom spanning panels engage the inner and outer structural members and position the inner structural member a predetermined distance from the outer structural member. 
     
     
         19 . The modular block system of  claim 16 , wherein the engagement rails of the bottom spanning panel are adapted to receive a second retaining feature of the top spanning panel of the at least one vertically adjacent block module. 
     
     
         20 . The modular block system of  claim 16 , wherein the top and bottom spanning panels are made of plastic.