FIELD OF THE INVENTION
This invention relates to components for construction generally, and is more specifically directed to building blocks for constructing and/or supporting walls, barriers, dams and the like.
BACKGROUND OF THE INVENTION
Barriers, such as walls, dams, fences and other similar structures are commonly formed of a plurality of blocks. The blocks may be formed of masonry materials, ceramics, metals and other materials.
There is a need for building blocks that are formed of shapes that are easily stacked, and easily connected. There is a need for blocks having elastic properties that are sufficiently rigid to bear substantial loading. Preferably, the blocks are made of commonly available and recyclable materials.
SUMMARY OF THE INVENTION
The present invention is a block having an elongated and hexagonal shape. A central void runs through the block. The block is formed of an elastomeric and water-repellant material.
The hexagonal shape facilitates stacking of blocks having identical hexagon dimensions, although the elongated dimension, or length, of the blocks may be different. The central void of the block may be filled with one or more materials that impart additional characteristics to the block and the resulting structure. The central void of the block may be filled with a material that resists deformation under load, or which resists impact or which absorbs energy, for example.
A plurality of the blocks may be used to form a barrier, such as a wall, bridge, fence or dam. The blocks may be used to support or stabilize structures. The blocks may reflect solid materials and/or liquid materials and/or absorb energy, including impact and acoustic energy, or act as a conduit for water or other liquids.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a building block according to an embodiment of the invention.
FIG. 2 is an elevation showing a hexagonal first end of a building block according to an embodiment of the invention.
FIG. 3 is a side elevation of a building block according to an embodiment of the invention.
FIG. 4 is a sectioned view of the building block shown in FIG. 3.
FIG. 5 is a sectioned view of the building block of FIG. 4, showing a central void of the building block filled with foam.
FIG. 6 is a sectioned view of the building block of FIG. 4, showing a central void of the building block filled with soil.
FIG. 7 is a sectioned view of the building block of FIG. 4, showing a central void of the building block filled with concrete.
FIG. 8 is a sectioned view of the building block of FIG. 4, showing a central void of the building block filled with aggregate, such as rock, gravel or stone.
FIG. 9 and FIG. 10 demonstrate connection of multiple building blocks along a common longitudinal axis by a connector located in the central void.
FIG. 11 and FIG. 12 demonstrate alternate embodiments of structural reinforcing material placed within the building blocks.
FIG. 13 is a sectioned view of the building block of FIG. 12.
FIG. 14 is a perspective view of an embodiment of a building block with a connecting member attached to an end of the building block.
FIG. 15 is an elevation of the first end of the building block of FIG. 14.
FIG. 16 demonstrates a side elevation of the building block of FIG. 14.
FIG. 17 is an isolation of the connector of the building block of FIG. 14.
FIG. 18 demonstrates use of the building block of FIG. 14.
FIG. 19 shows a plurality of stacked building blocks according to an embodiment of the invention.
FIG. 20 demonstrates a stacking configuration for the building blocks.
FIG. 21 presents an alternative stacking configuration for the building blocks.
FIG. 22 demonstrates yet another stacking configuration for the building blocks.
FIG. 23 demonstrates still another stacking configuration for the building blocks.
FIG. 24 demonstrates adjoining building blocks with the axis of the central void in a vertical configuration.
FIG. 25 demonstrates an alternative use of the building blocks.
FIG. 26 demonstrates a building block having a plurality of holes that connect the central void with an exterior of the building blocks.
FIG. 27 is a perspective view of an embodiment of the building block showing alignment marks on the block.
FIG. 28 is an elevation of an end of an embodiment of the building block showing alignment marks on the block.
FIG. 29 is a perspective view of an embodiment of the building block showing arcuate corners formed where the sides of the block meet.
FIG. 30 is an elevation of an end of an embodiment of the building block showing arcuate corners formed where the sides of the block meet.
FIG. 31 is a top plan view of a structure that may be used for vehicular control.
FIG. 32 is a partially sectioned elevation of a structure with blocks positioned under a rigid base with ends of the blocks aligned with the central voids forming a conduit.
FIG. 33 is a bollard formed by a block or blocks positioned vertically and filled or partially filled with a material such as concrete.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention is a building block component that is useful in building a structure. The building blocks may be used to support or stabilize structures. The blocks may reflect solid materials, and repel liquid materials and/or sound waves. The blocks comprise a hexagonal shape about an outer perimeter, and have a central void, which may be round. The central void may be filled with a second material, which may be concrete, metal, earth, rock aggregate, synthetic material or a combination thereof.
The blocks are preferred to be made of an elastomeric and water repellant material. The blocks may be made from natural or synthetic rubber. The rubber may be crumb and/or buffing material, which may be derived from automotive tires, and preferably, used tires. Other products, such as fly ash and/or cement may be added to the crumb and buffing mixture to increase density of the material.
FIG. 1-FIG. 4 show a building block 2 of a preferred embodiment. The building block as shown has an equilateral hexagonal outer perimeter, with the overall block being elongated from each end. The block is formed of an elastomeric and water repellent material. The block is elongated in shape, having a length as desired. The minimum dimension for blocks that are useful in building structures as contemplated by the invention is 15 centimeters measured from one flat side that makes up the hexagon of the block to an opposite flat side of the block.
The block has a central void 4. In a preferred embodiment, the central void has a round cross-section that is perpendicular to the central axis of the round void. The central void may be cylindrical, and extend from a first end to an opposite or second end of the block. The central void may open at one or both ends of the block, and closed at or near one or both ends of the block. The round cross section provides excellent structural loading characteristics to the block, while being easy to manufacture and easy to fill with a material. The central void may be of others shape as desired by the user. The central void is preferred to have a diameter of not less than 5 centimeters. The wall thickness of the block with a central void is preferred to be not less than 1.5 centimeters.
The use of an equilateral hexagonal perimeter, along with a round central void, yields a structure that can be oriented with any of the six sides positioned up or down, and in any of the six positions, while providing substantially identical structural integrity in any orientation.
FIG. 5-FIG. 8 demonstrate the central void filled with various materials, such as foam 32, soil or earth 34, concrete 36, or aggregate 38. Filling the central void with other materials modifies the structural characteristics of the block. Additional rigidity can be provided by filling the central void with aggregates, including rock, stone or concrete. Such materials are readily available, but are heavy to transport. Accordingly, the building blocks may be shipped with the central void empty, thereby reducing the shipping weight, with the central void filled with the second material at the construction site. The central void of the building blocks acts as a mold and/or container for the second material.
The central void may be filled with materials such as sand, earth or soil; foam, such as flowable polyurethane foam; aggregates, such as gravel or rock; and materials such as concrete or grout that are flowable and harden.
The blocks may be used in combination to form a structure that resists impact by the absorption of energy from the impact. The central void of the blocks may be filled with energy absorbing materials that are compressible upon impact. Such materials include foam, such as closed cell and open cell foam, and flowable foam, including polyurethane foam. Sorbothane®, Bubble Wrap, and other energy absorbing materials may be used alone, or in combination. Some or all of the blocks may be filled with one or more of these materials.
The blocks may be used in combination to form a structure that absorbs sound energy from impact, or to form an acoustic barrier. The central void of the blocks may be filled with materials that absorb sound energy. Such materials include foam as described above; fibers, such as matted or spun fibers; materials having an impervious surface mounted over an airspace; and resonators connected to an enclosed volume of trapped air. Some or all of the blocks may be filled with one or more of these materials.
The blocks may be joined end-to-end by the use of a connector. The connector is preferred to have substantially the same shape as the central void. As demonstrated in FIG. 9 and FIG. 10, the connector may be a round, generally cylindrical shape, yielding what may be described as a pin 6. The pin is inserted into a first block with a portion extending into a second, and adjoining block. The pins may build up in the central void by interference fit. The blocks are then assembled end-to-end as shown in the drawing figures.
One or more reinforcing materials may be added to the rubber structure to provide additional support and structural integrity to the walls of the blocks. Reinforcement may be accomplished, for example, by placing fibrous material, which may be a synthetic material, into the rubber structure, or by placing composite rings 8, 12 or spirals 10 into the rubber structure, or by placing steel reinforcement bars into the rubber structure. FIG. 11, FIG. 12, FIG. 13. The reinforcing material may be metal rings or spirals of various dimensions. The rings or spirals may be positioned along the length of the blocks as needed or desired, and a series of rings, or one or more spirals, may extend entirely, or partially, from a first end of the void to the second end of the void. Particularly where the building blocks have an open central void, for use as a conduit or a storage cavity, it is not desirable to fill the central void with a second material, and reinforcement materials such as rings or spirals are preferred. The reinforcing materials may be synthetic fibers, such as aramid and/or nylon fibers, composite materials, or metals such as steel or other alloys, such as stainless steel that resists corrosion. The blocks may be reinforced by adding metal strands, or rebar to the elastomeric material. The reinforcing materials may be placed longitudinally, and generally parallel to the longitudinal axis of the central void, or may be otherwise positioned to provide strength as required according to the application for the blocks.
In one embodiment, a connector 14 may be present on an end of the building blocks. The connector is designed to engage either another building block having a void shaped so as to receive the connector (FIG. 14), or the connector may be present on another structure, with the block having a void to receive the connector. FIG. 18. The connector may be of various shapes and configurations. A connector 14 having a six pointed star shape is demonstrated by FIGS. 14-18. The six pointed star shape is particularly adapted to align with and be held within the female six pointed star shape void 20 of the building blocks as shown in the drawing figures. The pins 16 extending from the connector that engage the building block hold the connector firmly in place. As shown in FIG. 18, a plurality of building blocks may be connected to another structure, such as a wall, in which a connector, such as connector 14, is mounted, by void 20 of the building blocks.
A structure may be formed by positioning the blocks with sides of a block adjoining one or more sides of other blocks having the same hexagonal dimensions. FIG. 19 shows the building blocks used to form a portion of a wall or other similar structure. While FIG. 19 shows the blocks in a two-block by five-block arrangement, the overall height and width of a wall, fence or other structure may be formed to the height and width desired by the user. The central void may be filled with a second material as described herein to achieve desired structural characteristics, or the central void of the block may be left open to facilitate the flow of liquid materials there through, or to allow for expansion and contraction of the blocks, or to use the void as storage for objects or devices. A honeycomb structure as shown may be constructed to the desired height and length through the use of multiple blocks as required.
The length of the blocks may be identical in one application. However, in other applications, the length of the blocks may not be identical, as shown in FIG. 20. In FIG. 20, the blocks are of unequal length, and are used as a wall that is adjacent to a material, which could be soil 22, concrete or other material. For example, the wall may be used hold the soil or other material to prevent collapse, or retard the soil or other material from eroding. In FIG. 20, the blocks are positioned so that a front face of the blocks is flat. However, in FIG. 21, the blocks are of unequal length, and are stacked in a configuration so that the blocks have a staggered face on each end of the blocks. Soil 22 or other material is on either side of the wall or structure formed by the blocks, with the blocks supporting or separating the soil or other material, or adding structure to soil or other material. Designs or configurations may be formed by staggering the blocks. Ends of the blocks may be cut or shaped to form a desired shape in the overall construct.
FIG. 22 demonstrates an arrangement of the blocks wherein the blocks are attached to an object, such as a rigid and planar base, and suspended there from. In the particular embodiment as shown, the blocks are suspended from a wooden beam or wooden deck 24. Known fasteners and connection devices may be used to connect the blocks. Alternatively, the blocks may support the object, such as a rigid and planar base 24. FIG. 32. The blocks may form decking for a bridge, wherein the decking is the base, which may be planar and rigid in form for pedestrian or vehicular traffic. If the central void is left open, the blocks provide a conduit 45 for liquid flow through the blocks. Blocks may be positioned and/or joined end to end so that the central voids align and form a conduit.
FIG. 23 demonstrates the building blocks stacked in an irregular formation. A first end of some of the plurality of blocks is recessed relative to a first end of others of the plurality of blocks as the plurality of blocks is stacked to form a structure.
FIG. 24 demonstrates the blocks with the axis of the central void extending vertically. For demonstration purposes as shown, the building blocks are used as a planter, with soil present in the central void, and plants 26 growing in the soil in the central void. Vertically positioned blocks may also be used as pavers, and may be filled with soil, sand, concrete, rock or other materials. The top surfaces of the blocks are preferred to be in substantially the same plane when used to form a driveway or walkway or similar structure when used as pavers.
The blocks may be used to form barriers such as vertically extending bollards 46. FIG. 33. The blocks, which are relatively light in weight, may be positioned, then filled with materials to anchor the blocks. For example, the block may be positioned in front of another structure that the block protects, such as a parking ticket dispenser in a parking garage, and filled with concrete 48 after positioning to anchor the resulting bollard.
FIG. 25 demonstrates a building block's central void used for storage of a device or object. In this case, the building block is used for storage of a wine bottle 28. The blocks can be stacked as demonstrated herein to form a storage rack and to provide storage for multiple bottles of wine or other objects.
FIG. 26 identifies a building block 102 having a plurality of voids 106 that extend from the exterior of the building block into the interior of the central void 104. Holes or voids such as these may be used as weep holes for drainage of one or a plurality of blocks. The plurality of blocks may be drained by aligning the weep holes. Again, it is preferred that the six sides of the blocks are equilateral and substantially identical, so that positioning and/or stacking of the blocks is effective no matter which side is placed up or down when stacking the blocks. By aligning the holes, and filling the central void with a flowable material that hardens, a plurality of adjoining blocks may be connected by the flowable material. The flowable material could be a polyurethane or similar hydrogen reactive material, such as those comprising isocyanate, or grouting materials, or concrete.
As shown in FIG. 27 and FIG. 28, alignment marks 40 may be etched or formed or printed on the blocks. In a preferred embodiment, there are six alignment marks, with one alignment mark corresponding to each side of the blocks and formed halfway along the length of the side. The alignment mark may be aligned with the alignment mark of an adjoining block to assist alignment and assembly of the structure.
FIG. 28 and FIG. 29 demonstrate an embodiment of the blocks having rounded or arcuate corners 42, rather than sharp corners.
FIG. 31 demonstrates a structure that may be used as a funnel for a flow of traffic or materials. For example, the structure may provide a traffic barrier that extends into a lane of traffic, with the plurality of unequal length blocks mounted at an angle, such as a 30° to 60° angle, on a vertical structure, such as a wall or barrier 44. The resilient nature of the blocks absorbs impact in the event that the block is struck by a vehicle.
The maximum length of a block is limited only by manufacturing and transportation criteria. Dimensionally, the size of a block will be determined by the design of each specific project detail, for example, a paver type block may have a parallel sides dimension of 8 inches with a central void diameter of 6 inches, whereas a unit to be used in a waterway may have an exterior dimension of 24 inches with a central void diameter of 18 inches. The block may be manufactured by compression molding, injection molding, or extrusion or pultrusion techniques.
The block according to the invention is substantially lighter in weight than concrete or masonry blocks of corresponding size. The block can be easily carried by a person and positioned as required to form a structure with the blocks. The central void can be filled with concrete or other materials as described herein after assembly of the blocks in many cases.
Patent Application
20140075854
