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Patent US4214408A successfully refreshed from Google Patents.
US4214408A
Expired / Lapsed
US
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Monolithic room enclosing module and method of forming the same
Assignee: F D RICH HOUSING CORP
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Filing: 1978-05-08
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Granted: 1980-07-29
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Expires: 1998-05-08
Abstract
Abstract In a method for forming a module having a floor, a roof and opposing sides, a concrete floor is first poured and, once solidified, moved into position between tilted wall molds. Inexpensive hollow masonry blocks are then dry-stacked in rows against the wall molds; that is, they are loosely stacked without mortar therebetween. Spaces with reinforcing rods therein are left along the outer wall molds at each end of the stacked blocks. Inner wall molds and, for some modules, a roof mold are then moved into place adjacent the stacked blocks. With the wall molds vertical, the blocks are pressed between the inner and outer wall molds. Concrete is poured into the spaces at each end of the stacks of blocks to form structural posts and over the tops of the stacks of blocks to form structural spandrel beams. Additional hollow blocks are laid across the roof mold and concrete is poured over those blocks to complete the roof. Once the concrete has cured, the outer wall molds are tilted away, and the molded structure is moved to another station. At the second station, the inner molds are removed and the blocks, held in compression by the weight of the spandrel, are coated with stucco to bind the blocks to each other. End walls are also constructed at this station. The resulting module includes a roof primarily supported by structural posts and spandrel beams. Stacked blocks forming the walls of the module are in compression to assure sufficient friction between the blocks for structural stability of the walls. Structural stability of the blocks is enhanced by the cementitious stucco coating.
Inventors
- 👤 Frank D. Rich, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 14:23
CPC Classifications
B; B28; B28B; B28B7/00; B28B7/22; E; E04; E04B; E04B1/00; E04B1/348; E04B1/34815; E04B1/34823
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
222 words
The method of forming a monolithic room-enclosing module comprising the steps of providing a unitary wall-supporting base slab; dry-stacking a plurality of rows of blocks on said base slab to form the major portions of at least two opposed module walls; and thereafter pouring a plastic structural material into a first mold adjacent one end of each wall of dry-stacked blocks to form structural posts at least at one end of each module wall of said dry-stacked blocks but not substantially within or between the individual blocks, said structural posts providing lateral support for said dry-stacked blocks; pouring a plastic structural material into a second mold over the top of each module wall of said dry-stacked blocks to form a structural spandrel beam over each wall of said dry-stacked blocks, the weight of said spandrel beam acting on said dry-stacked blocks therebelow to hold said dry-stacked blocks in close compressive relationship with each other for providing each of said module walls with structural stability; joining said spandrel beams with a roof spanning said base slab; and coating at least one face of each of said module walls of dry-stacked blocks with a skin of cementitious material after removal of said first and second molds to provide a continuous surface coating over said at least one face of each of said module walls.
Claim 2
Independent Claim
222 words
The method of forming a monolithic room-enclosing module comprising the steps of providing a unitary wall-supporting base slab; dry-stacking a plurality of rows of blocks on said base slab to form the major portions of at least two opposed module walls; and thereafter pouring a plastic structural material into a first mold adjacent one end of each wall of dry-stacked blocks to form structural posts at least at one end of each module wall of said dry-stacked blocks but not substantially within or between the individual blocks, said structural posts providing lateral support for said dry-stacked blocks; pouring a plastic structural material into a second mold over the top of each module wall of said dry-stacked blocks to form a structural spandrel beam over each wall of said dry-stacked blocks, the weight of said spandrel beam acting on said dry-stacked blocks therebelow to hold said dry-stacked blocks in close compressive relationship with each other for providing each of said module walls with structural stability; joining said spandrel beams with a roof spanning said base slab; and coating at least one face of each of said module walls of dry-stacked blocks with a skin of cementitious material after removal of said first and second molds to provide a continuous surface coating over said at least one face of each of said module walls.
Claim 3
Dependent Claim
43 words
The method of forming a monolithic room-enclosing module as claimed in claim 1 wherein said dry-stacked blocks are pressed between inner and outer wall molds and said structural posts and structural spandrel beams are poured between those same inner and outer wall molds.
Claim 4
Dependent Claim
62 words
The method of forming a monolithic room-enclosing module as claimed in claim 1 wherein said roof is formed by laying blocks across a roof mold in rows with spaces between rows of blocks extending between said structural spandrel beams and pouring a plastic structural material over said rows of blocks, structural material flowing into the spaces between the blocks forming structural ribs.
Claim 5
Dependent Claim
64 words
The method of forming a monolithic room-enclosing module as claimed in claim 3 wherein said roof is pitched and said blocks have holes therethrough and are aligned to form channels extending from the eaves of the module toward its peak, and said channels are exposed to the atmosphere at each end thereof after the concrete is poured in order to convect heated air therethrough.
Claim 6
Dependent Claim
24 words
The method of forming a monolithic room-enclosing module as claimed in claim 1 wherein said stacked blocks have an interengaging tongue and groove configuration.
Claim 7
Independent Claim
297 words
The method of forming a monolithic room-enclosing module comprising the steps of providing a unitary wall-supporting base slab between opposed outer wall molds; dry-stacking a plurality of rows of blocks on said base slab against each of said outer wall molds to form the major portions of at least two opposed module walls, but not dry-stacking said blocks in spaces at each end of said wall molds and at the tops of said wall molds; providing an inner mold on said base slab between said two opposed module walls of dry-stacked blocks with said blocks pressed between said inner mold and said outer wall molds; and thereafter pouring a plastic structural material between said inner mold and said outer wall molds at each end of said module walls of dry-stacked blocks to form structural posts but not pouring said plastic structural material substantially within or between the individual blocks, said structural posts providing lateral support for said dry-stacked blocks; pouring a plastic structural material between said inner mold and said outer wall molds over the top of each of said module walls of dry-stacked blocks to form a structural spandrel beam over each of said module walls, the weight of said structural spandrel beam acting on said dry-stacked blocks therebelow to hold said dry-stacked blocks in close compressive relationship with each other for providing each of said module walls with structural stability; supporting a roof on said structural posts and said structural spandrel beams; moving said inner mold and said outer wall molds away from said module walls; and coating at least one face of each of said module walls of dry-stacked blocks with a skin of cementitious material to provide a continuous surface coating over said at least one face of each of said module walls.
Claim 8
Independent Claim
297 words
The method of forming a monolithic room-enclosing module comprising the steps of providing a unitary wall-supporting base slab between opposed outer wall molds; dry-stacking a plurality of rows of blocks on said base slab against each of said outer wall molds to form the major portions of at least two opposed module walls, but not dry-stacking said blocks in spaces at each end of said wall molds and at the tops of said wall molds; providing an inner mold on said base slab between said two opposed module walls of dry-stacked blocks with said blocks pressed between said inner mold and said outer wall molds; and thereafter pouring a plastic structural material between said inner mold and said outer wall molds at each end of said module walls of dry-stacked blocks to form structural posts but not pouring said plastic structural material substantially within or between the individual blocks, said structural posts providing lateral support for said dry-stacked blocks; pouring a plastic structural material between said inner mold and said outer wall molds over the top of each of said module walls of dry-stacked blocks to form a structural spandrel beam over each of said module walls, the weight of said structural spandrel beam acting on said dry-stacked blocks therebelow to hold said dry-stacked blocks in close compressive relationship with each other for providing each of said module walls with structural stability; supporting a roof on said structural posts and said structural spandrel beams; moving said inner mold and said outer wall molds away from said module walls; and coating at least one face of each of said module walls of dry-stacked blocks with a skin of cementitious material to provide a continuous surface coating over said at least one face of each of said module walls.
Claim 9
Dependent Claim
37 words
The method of forming a monolithic room-enclosing module as claimed in claim 6 wherein said outer wall molds are tilted away from said wall supporting base slab when said blocks are dry-stacked against said outer wall molds.
Claim 10
Dependent Claim
62 words
The method of forming a monolithic room-enclosing module as claimed in claim 6 wherein said roof is formed by laying blocks across a roof mold in rows with spaces between rows of blocks extending between said structural spandrel beams, and pouring a plastic structural material over said rows of blocks, structural material flowing into the spaces between the blocks forming structural ribs.
Claim 11
Dependent Claim
65 words
The method of forming a monolithic room-enclosing module as claimed in claim 8 wherein said roof is pitched and said blocks have holes therethrough and are aligned to form channels extending from the eaves of the module toward its peak, and said channels are exposed to the atmosphere at each end thereof after the concrete is poured whereby heated air may pass therethrough by convection.
Claim 12
Dependent Claim
154 words
A monolithic room-enclosing module comprising: a unitary wall-supporting base slab, opposed module walls of dry-stacked rows of abutting low-density blocks on said base slab; structural posts of higher density material formed adjacent each end of each of said walls of dry-stacked blocks for laterally supporting said dry-stacked blocks, a structural spandrel beam of higher density material formed over each of said module walls of dry-stacked low-density blocks, the weight of said structural spandrel beam acting on said dry-stacked blocks therebelow to maintain said dry-stacked blocks in close compressive relationship with each other for providing each of said module walls with structural stability; a roof bridging said module walls and supported by said structural posts and said structural spandrel beams; and a skin of cementitious material over at least one face of each of said module walls to provide a continuous surface coating over said at least one face of each of said module walls.
Claim 13
Dependent Claim
154 words
A monolithic room-enclosing module comprising: a unitary wall-supporting base slab, opposed module walls of dry-stacked rows of abutting low-density blocks on said base slab; structural posts of higher density material formed adjacent each end of each of said walls of dry-stacked blocks for laterally supporting said dry-stacked blocks, a structural spandrel beam of higher density material formed over each of said module walls of dry-stacked low-density blocks, the weight of said structural spandrel beam acting on said dry-stacked blocks therebelow to maintain said dry-stacked blocks in close compressive relationship with each other for providing each of said module walls with structural stability; a roof bridging said module walls and supported by said structural posts and said structural spandrel beams; and a skin of cementitious material over at least one face of each of said module walls to provide a continuous surface coating over said at least one face of each of said module walls.
Claim 14
Dependent Claim
47 words
The monolithic room-enclosing module as claimed in claim 10 wherein said roof comprises spaced rows of low-density blocks extending between said spandrel beams and a layer of higher density material covering said low-density blocks and filling the spaces between said rows of blocks to encapsulate said blocks.
Claim 15
Dependent Claim
62 words
The monolithic room-enclosing module as claimed in claim 11 wherein said roof is pitched so as to have a peak and said low-density blocks in said roof have holes therethrough and are aligned to provide channels extending from the eaves of said roof toward its peak, the ends of said channels being exposed to the atmosphere for air convection through said channels.
Claim 16
Dependent Claim
29 words
A monolithic room-enclosing module as claimed in claim 12 further comprising a water shedding cap supported by said roof over the exposed ends of said channels near said peak.
Claim 17
Dependent Claim
22 words
A monolithic room-enclosing module as claimed in claim 11 wherein said roof further comprises reinforcing rods embedded in said higher density material.
Claim 18
Dependent Claim
15 words
A monolithic room-enclosing module as claimed in claim 10 wherein said cementitious material is stucco.
Claim 19
Dependent Claim
16 words
A monolithic room-enclosing module as claimed in claim 10 wherein said higher density material is concrete.
Claim 20
Dependent Claim
20 words
A monolithic room-enclosing module as claimed in claim 10 wherein said stacked low-density blocks have a tongue and groove configuration.
Claim 21
Dependent Claim
117 words
A unitary prefabricated room-enclosing module including a base portion, at least two opposing sides, and a roof supported by said sides and spanning said base portion: said at least two opposing sides each including dry-stacked rows of abutting blocks on said base portion, a poured concrete spandrel beam on the top of said dry-stacked blocks, the weight of said spandrel beam compressing said blocks against one another with sufficient force to hold said blocks in tight frictional engagement to provide structural stability, and poured concrete corner posts only at each end of said blocks and joined by said spandrel beams, said corner posts further holding said blocks in position and providing lateral support to said dry-stacked blocks.
Claim 22
Dependent Claim
117 words
A unitary prefabricated room-enclosing module including a base portion, at least two opposing sides, and a roof supported by said sides and spanning said base portion: said at least two opposing sides each including dry-stacked rows of abutting blocks on said base portion, a poured concrete spandrel beam on the top of said dry-stacked blocks, the weight of said spandrel beam compressing said blocks against one another with sufficient force to hold said blocks in tight frictional engagement to provide structural stability, and poured concrete corner posts only at each end of said blocks and joined by said spandrel beams, said corner posts further holding said blocks in position and providing lateral support to said dry-stacked blocks.
Claim 23
Dependent Claim
65 words
A unitary prefabricated room-enclosing module as claimed in claim 18 wherein said roof is pitched so as to have a peak and comprised blocks encapsulated in poured concrete, said blocks having holes therethrough and being aligned to provide channels extending from the eaves of the roof toward its peak, the ends of said channels being exposed to the atmosphere for air convection through said channels.
Claim 24
Dependent Claim
29 words
The improvement in a monolithic room-enclosing module as claimed in claim 18 wherein rows of said blocks are spaced and the encapsulating material of said roof fills those spaces.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-07-29 | 1984-01-28 | 1984-07-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-07-29 | 1988-01-28 | 1988-07-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-07-29 | 1992-01-28 | 1992-07-29 | $7700.00 | Window Closed / Lapsed |