Interlocking masonry system

Abstract

A structural masonry element includes an element body having a perimeter wall defined by height, and having parallel top and bottom surfaces, each of the top and bottom surfaces having an external lunate shape. The external lunate shape is defined by a material section resulting from a symmetrical lens cut away from a first circle. The symmetrical lens is a result of an intersection of the first circle with a second circle. Radii of the first and second circles are equivalent. A distance between centers of the first circle and second circle is greater than each of the first and second radii. The external lunate shape is configured to nest an analogous interfacing masonry element within the symmetrical lens and thereby provide a spherical first interlocking masonry joint. A mortarless masonry structure including a plurality of such masonry elements is also considered.

What is claimed is: 
     
         1 . A masonry element comprising:
 an element body having a perimeter wall defined by a height and having parallel top and bottom surfaces, each of the top and bottom surfaces having an external lunate shape;   wherein:
 the external lunate shape is defined by a material section resulting from a symmetrical lens cut away from a first circle having a first radius, 
 the symmetrical lens is a result of an intersection of the first circle with a second circle having a second radius equivalent to the first radius; 
 a distance between a center of the first circle and a center of the second circle is greater than each of the first and second radii; and 
 the external lunate shape is configured to nest an analogous interfacing masonry element within the symmetrical lens and thereby provide a spherical first interlocking masonry joint. 
   
     
     
         2 . The masonry element of  claim 1 , wherein each of the top and bottom surfaces additionally has an internal lunate shape, thereby defining a hollow section arranged concentrically with and oriented same as the external lunate shape, and wherein the internal lunate shape is configured to accept a reinforcement material therein. 
     
     
         3 . The masonry element of  claim 2 , wherein the top surface defines a groove configured to accept a horizontal first rebar element or a first tensioning cable extending across each of the external and internal lunate shapes. 
     
     
         4 . The masonry element of  claim 2 , wherein the bottom surface defines a groove configured to accept a horizontal second rebar element or a second tensioning cable extending across each of the external and internal lunate shapes. 
     
     
         5 . The masonry element of  claim 2 , wherein the element body additionally defines a fillet relief in a corner of the internal lunate shape configured to accept a vertical third rebar element or a third tensioning cable extending along the perimeter wall. 
     
     
         6 . The masonry element of  claim 1 , wherein:
 the element body includes a longitudinal axis;   the perimeter wall is arranged along the longitudinal axis; and   the perimeter wall includes an outer section having a first slanted surface.   
     
     
         7 . The masonry element of  claim 6 , wherein the first slanted surface has a concave profile. 
     
     
         8 . The masonry element of  claim 6 , wherein the bottom surface is inset relative to the perimeter wall toward the top surface, and wherein the element body includes an inner section having a second slanted surface between the perimeter wall and the inset bottom surface configured to interface with and nest a first slanted surface of an analogous second interfacing masonry element when the analogous second interfacing masonry element is arranged against the bottom surface to nest therein and thereby provide a tapered second interlocking masonry joint. 
     
     
         9 . The masonry element of  claim 1 , wherein the element body is provided from high-density pressed concrete formed under a 12-14 MPa load. 
     
     
         10 . The masonry element of  claim 1 , wherein each of the first and second radii is 4.00 inches, and the distance between the center of the first circle and the center of the second circle is 5.6 inches. 
     
     
         11 . A mortarless masonry structure comprising:
 a plurality of masonry elements, wherein each masonry element includes:   an element body having a perimeter wall defined by height and having parallel top and bottom surfaces, each of the top and bottom surfaces having an external lunate shape;   wherein:
 the external lunate shape is defined by a material section resulting from a symmetrical lens cut away from a first circle having a first radius, 
 the symmetrical lens is a result of an intersection of the first circle with a second circle having a second radius equivalent to the first radius; 
 a distance between a center of the first circle and a center of the second circle is greater than each of the first and second radii; 
 the external lunate shape is configured to nest an analogous interfacing masonry element within the symmetrical lens and thereby provide a spherical first interlocking masonry joint therebetween; and 
 at least one of the top surface and the bottom surface is configured to nest therein a second interfacing masonry element and thereby provide a tapered second interlocking masonry joint. 
   
     
     
         12 . The mortarless masonry structure of  claim 11 , wherein each of the top and bottom surfaces additionally have an internal lunate shape, thereby defining a hollow section arranged concentrically with and oriented same as the external lunate shape, and wherein the internal lunate shape is configured to accept a reinforcement material therein. 
     
     
         13 . The mortarless masonry structure of  claim 12 , further comprising a horizontal first rebar element or a first tensioning cable, wherein the top surface defines a groove configured to accept the horizontal first rebar element or the first tensioning cable extending across each of the external and internal lunate shapes. 
     
     
         14 . The mortarless masonry structure of  claim 12 , further comprising a horizontal second rebar element or a second tensioning cable, wherein the bottom surface defines a groove configured to accept a horizontal second rebar element or a second tensioning cable extending across each of the external and internal lunate shapes. 
     
     
         15 . The mortarless masonry structure of  claim 12 , further comprising a plurality of masonry finishing blocks, each configured to be mounted to and cover the hollow section in one of the plurality of masonry elements. 
     
     
         16 . The mortarless masonry structure of  claim 11 , further comprising a plurality of base masonry blocks configured to be mounted to a structural foundation and interface with at least some of the plurality of masonry elements;
 wherein:
 each base block includes top and bottom surfaces, each of the top and bottom surfaces of the base masonry blocks having an external lunate shape; 
 the external lunate shape of the masonry base block is configured to interface with and nest a masonry base block to thereby generate a base masonry layer; 
 the top surface of each masonry base block is configured to interface with and nest within the bottom surface of one of the plurality of masonry elements; and 
 the bottom surface of each masonry base block is configured to interface with the structural foundation. 
   
     
     
         17 . The mortarless masonry structure of  claim 16 , wherein each masonry base block additionally defines a first aperture extending perpendicular to each of the top and bottom surfaces and configured to accept a fastener to thereby attach the masonry base block to the structural foundation. 
     
     
         18 . The mortarless masonry structure of  claim 16 , further comprising a vertical third rebar element or a third tensioning cable, wherein each masonry base block additionally defines a second aperture extending perpendicular to each of the top and bottom surfaces and configured to accept the vertical third rebar element or the third tensioning cable extending through at least one of the plurality of masonry elements located above the masonry base block and thereby strengthen the masonry structure. 
     
     
         19 . The mortarless masonry structure of  claim 16 , further comprising an adhesive applied to at least one of the first and second interlocking masonry joints and between the bottom surface of each masonry base block and the structural foundation. 
     
     
         20 . The mortarless masonry structure of  claim 11 , wherein at least a section of the masonry structure is configured as a curved wall layout arranged in a horizontal plane. 
     
     
         21 . The mortarless masonry structure of  claim 11 , wherein at least a section of the masonry structure includes a masonry direction-changing block having a bidirectional external lunate shape. 
     
     
         22 . The mortarless masonry structure of  claim 21 , wherein at least a section of the masonry structure is configured as an arc arranged in a vertical plane, and wherein the arc includes the masonry direction-changing block. 
     
     
         23 . The mortarless masonry structure of  claim 11 , wherein at least a section of the masonry structure includes one or more corner blocks, each having a fully cylindrical shape configured to interface with at least one of the masonry elements and thereby provide a nesting transition between adjacent or intersecting walls.