A portion of the disclosure of this patent document contains material which is subject to copyright protection. This patent document may show and/or describe matter which is or may become trade dress of the owner. The copyright and trade dress owner has no objection to the facsimile reproduction by anyone of the patent disclosure as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright and trade dress rights whatsoever.
This disclosure relates to construction blocks, and, more particularly, to interlocking construction blocks.
Habitable structures, such as those used for houses, businesses, and storage, need to be constructed of sturdy and durable materials that can withstand various weather conditions over time to usefully protect the people and things inside the structure. Further, the materials should also be sturdy enough to deter or prevent unwanted intruders, whether animal or human. These materials are also ideally resistant to mold, fungus, water damage, insect damage, and other types of decay. The materials must also not make the environment inside the structure toxic to the inhabitants, for example, by emitting poisonous vapors or particles into the air inside the structure
Some traditional construction materials for building structures, such as concrete, cinder blocks, metal, and bricks, can be expensive, heavy to transport, and unwieldy to manipulate during the construction process. Further, these traditional construction materials typically require additional bonding material, such as mortar, to bond the construction materials in a useful way. The bonding material can also be expensive, heavy, and require laborious mixing with water.
Other types of construction materials, such as wood, stucco, and vinyl, require time-consuming installation by a team of skilled workers with special tools, which can be expensive and slow the construction process. These materials can also be costly.
There is a great need for safe and affordable structures due to quickly rising housing costs and increasing numbers of homeless people. Improved construction materials that fulfill the sturdiness requirements of habitable structures, yet are inexpensive and easy to transport and manipulate, are desirable to help provide this suitable and affordable housing.
Throughout this description, elements appearing in figures are assigned three-digit or four-digit reference designators, where the two least significant digits are specific to the element and the one or two most significant digit is the figure number where the element is first introduced. An element that is not described in conjunction with a figure may be presumed to have the same characteristics and function as a previously described element having the same reference designator.
Construction block units disclosed herein are an improved material for constructing structures. Each construction block has structural elements to provide a light-weight, rigid, and stable building material. These construction blocks can be inexpensively manufactured and are lightweight to transport and manipulate. Further, the construction blocks can be coupled together without the need for additional materials such as mortar or cement. The construction blocks can include various sizes and shapes, and can be assembled together in various configurations to construct desired structures. The hollow interiors of the construction blocks can be filled with a weight, such as sand or water, to create sturdy and durable structure walls for various uses, such as for homes and businesses.
The construction block 110 can have any suitable size and dimensions for use in construction of structures. For example, the width of the construction block 110 can be in a range from 4 inches to 24 inches. A typical width of the construction block 110 can be in a range from 6 inches to 12 inches, such as 8 inches. Exemplary lengths of the construction block 110 can be in a range from 4 inches to 36 inches. A typical width of the construction block 110 can be in a range from 10 inches to 24 inches, such as 16 inches.
The construction block 110 has a substantially vertical sidewall 112 extending from an outer edge of a substantially planar bottom plate 116. The vertical sidewall 112 can be any suitable height for use in construction. For example, the vertical sidewall 112 can have a height in a range from 3 inches to 48 inches. Typical vertical sidewall 112 heights can be in a range from 6 inches to 24 inches, such as 8 inches. A thickness of the vertical sidewall 112 can be based on the material from which the sidewall is constructed. The thickness can be a suitable thickness to support the weight of materials used for weighting the construction block 110, such as sand or water, and support weight of additional materials positioned on top, such as additional construction blocks and roofing material. For example, the thickness can be in a range from 0.4 inches to 1.5 inches. A typical thickness can be in a range from 0.5 inches to 0.9 inches, such as 0.6 inches.
The bottom plate 116 has a shape corresponding to a bottom edge of the sidewall 112. The sidewall 112 connects to the bottom plate 116 to enclose an open space container 117 in the interior of the construction block 110, which is suitable for receiving and containing a weight. The sidewall 112 and the bottom plate 116 can be formed at the same time as one continuous piece. Alternatively, the sidewall 112 and the bottom plate 116 can be formed separately and then joined by any suitable means, such as an adhesive or melting contacting pieces together. A thickness of the bottom plate 116 can be any suitable thickness, and can be the same or different from the sidewall 112 thickness.
An interlocking portion including a tab 114a and a blank 114b are on one side of the construction block 110. The tab 114a and the blank 114b can be formed by bends and curves in the sidewall 112, and can extend vertically along some or all of the side. The tab 114a and the blank 114b are configured to interlock with a corresponding blank and tab of another construction block. For example, when viewed from above, one or more sections of a top of the sidewall appear to bend to form tabs, while one or more other sections can bend to form blanks, much like a puzzle piece. In the example shown in
To interlock the construction blocks 110 to construct a wall, a first construction block can be held above and aligned with a second construction block such that when the first construction block is lowered into place, the tab of the first construction block slides into the blank of the second construction block and the tab of the second construction block slides into the blank of the first construction block to interlock the sidewalls of the first construction block and the second construction block. For example, the corresponding blank and tab of another construction block can slide vertically into the tab and blank such that the construction blocks are interlocked. Horizontal forces are prevented from pulling the construction blocks apart when the construction blocks are interlocked. The construction blocks can be separated again by sliding one vertically with respect to the other.
The construction block 110 can have another interlocking portion including a tab 114c and a blank 114d on an opposite side of the construction block 110. Thus, the construction block 110 can be interlocked with other construction blocks on both sides. Many construction blocks can be interlocked to create a horizontal layer of a structure.
The sidewall 112 can be shaped to have either sharp corners or rounded corners, or may have some corners that are sharp while others are rounded.
The construction block 110 can include strengthening structural ribs 118 disposed on the walls at suitable intervals. In one example shown in
The construction block 110 can further include fasteners 120 for coupling the construction block to either a lid 150 or another construction block. The fasteners 120 can be located at ends of the structural ribs 118 that extend beyond a top edge 124 of the sidewall 112, or any other suitable location, e.g., along a top edge 124 of the sidewall 112. For example, the fasteners 120 can be cylindrical, like pegs, or can have several sides, such as three, four, or six sides. The fasteners 120 can have any suitable dimensions for coupling the construction block. For example, the fastener 120 can have a height in a range from 0.2 inches to 1 inch, such as 0.320 inches, and can have a thickness in a range from 0.2 inches to 0.5 inches, such as 0.245 inches.
The fasteners 120 can be received by a corresponding element of another construction block, such as an opening 122 on a bottom surface of the bottom plate 116. For example, the fasteners 120 can be received by the opening 122 with a friction fit. Thus, the dimensions of the opening 122 are dimensions that are suitable for receiving the fastener 120 with a friction fit. The construction block 110 may further be fastened to another construction block with adhesive, which can also be applied to the fasteners 120 and/or openings 152. In this way, the construction block 110 can be fastened to the top of another construction block. The top construction serves as a cover for the container 117 of the construction block positioned below to contain any weight in the container 117 and prevent any other materials from being placed in the lower construction block.
The number of fasteners 120 and corresponding openings 122 can be any suitable number for fastening one construction block to another. For example, the number of fasteners 120 and corresponding openings 122 can be in a range from 3 to 20. In
The lid 150 has a congruent shape to the bottom plate 116 and is configured to close the open space container 117 in the interior of the construction block 110. The lid 150 can have any suitable thickness to close the container 117, which may be the same or different from the thicknesses of the sidewalls 112 and the bottom plate 116. For example, the lid 150 can have a thickness of 0.6 inches.
The lid 150 has openings 152 positioned to correspond to and receive the fasteners 120 such that the lid 150 is fastenable to the construction block 110, for example, with a friction fit. The dimensions of the openings 152 are dimensions that are suitable for receiving the fastener 120 with a friction fit. In this way, the lid 150 can be fastened to the construction block 110. The lid 150 may further be fastened to the construction block 110 with adhesive, which can also be applied to the fasteners 120 and/or openings 152. For example, the lids can be fastened to construction blocks at the top of a wall being constructed. The lids can contain any weight in the container 117 and prevent any other materials from being placed in the lower construction block.
The construction block 110 and the lid 150 can be constructed of the same or different materials. For example, the construction block 110 and the lid 150 can be formed of plastics, polymers, composite materials, fiberglass, metal, foam, and recycled materials.
The container 117 can be filled with any suitable material to add weight to the construction block and stability to the structure, including, but not limited to, water, sand, concrete, dirt, rocks, and gravel.
A seal 125 can be positioned at the top edge 124 of the sidewall 122. The seal 125 seals the construction block 110 to either another construction block positioned above it or a lid 150 to further contain any weight in the container 117 and prevent any other materials from being placed in the container 117. The seal 125 can be any suitable material, such as foam, rubber, polymers, plastic, silicone, and wax. The seal 125 may also have an adhesive to adhere the seal 125 to construction block and/or the seal. The seal 125 can have any suitable thickness for sealing a lid or a construction block to another construction block. For example, the seal can have a thickness in a range from 0.05 inches to 0.3 inches, such as 0.1 inches.
The construction blocks can include other features that allow the construction blocks to be used with other building materials. For example, the construction blocks can have surfaces that are appropriately textured for painting or application of siding, stucco, adhesive, insulation, drywall, or plaster. The construction blocks may also be able to receive coupling devices, such as tacks, nails, or screws, so that other types of construction materials can be fastened to the construction blocks.
The construction blocks can be various shapes and sizes such that various different structures can be assembled from the blocks. The different construction blocks can include different shapes so that walls can be constructed at various angles. Construction blocks can also have shapes that allow for door and window openings. The construction blocks can be used to construct exterior and interior walls.
The first sidewalls 913 and second sidewalls 912 can be any suitable height for use in construction, as described above with respect to
The opposing first sidewalls 913 can be rotated on their hinges 980 (as shown by arrows 960 in
As shown in
The tab 914a and the blank 914b are configured to interlock with a corresponding blank and tab of another construction block, as described above with respect to
The construction block 910 can further include fasteners 920 for coupling the construction block to either the lid 950 or another construction block, as described above with respect to
The fasteners 920 can be received by a corresponding element of another construction block, such as an opening on a bottom surface of the bottom plate (not shown), or by an opening 952 in the lid 950. The fasteners 920 can be received with a friction fit. The construction block 910 may further be fastened to another construction block with adhesive, which can also be applied to the fasteners 920 and/or openings 952. The construction block 910 can be fastened to the top of another construction block. The top construction block serves as a cover for the container 917 of the construction block positioned below to contain any weight in the container 917 and prevent any other materials from being placed in the lower construction block. The number of fasteners 920 and corresponding openings 922 can be any suitable number for fastening one construction block to another. For example, the number of fasteners 120 and corresponding openings 122 and be in a range from 3 to 20.
The lid 950 has a congruent shape to the construction block when configured for use, and is configured to close the open space container 917 in the interior of the construction block 910. The lid 950 has openings 952 positioned to correspond to and receive the fasteners 920 such that the lid 950 is fastenable to the construction block 910, for example, with a friction fit. The dimensions of the openings 952 are dimensions that are suitable for receiving the fastener 920 with a friction fit. In this way, the lid 950 can be fastened to the construction block 910. The lid 950 may further be fastened to the construction block 910 with adhesive, which can also be applied to the fasteners 920 and/or openings 952. For example, the lids can be fastened to construction blocks at the top of a wall being constructed. The lid 950 can contain any weight in the container 917 and prevent any other materials from being placed in the lower construction block.
The construction block 910 and the lid 950 can be constructed of the same or different materials. For example, the construction block 910 and the lid 950 can be formed of plastics, polymers, composite materials, fiberglass, metal, foam, and recycled materials. The construction blocks can be various shapes and sizes such that various different structures can be assembled from the blocks. The different construction blocks can include different shapes so that walls can be constructed at various angles.
The container 917 can be filled with any suitable material to add weight to the construction block and stability to the structure, including, but not limited to, water, sand, concrete, dirt, rocks, and gravel.
A seal (not shown) can be positioned at the top edge 924 of the sidewall 912. The seal seals the construction block to either another construction block positioned above it or a lid to further contain any weight in the container and prevent any other materials from being placed in the container. The seal can be any suitable material, such as foam, rubber, polymers, plastic, silicone, and wax. The seal may also have an adhesive to adhere the seal to construction block and/or the seal. The seal can have any suitable thickness for sealing a lid or a construction block to another construction block.
Throughout this description, the embodiments and examples shown should be considered as exemplars, rather than limitations on the apparatus and procedures disclosed or claimed. Although many of the examples presented herein involve specific combinations of method acts or system elements, it should be understood that those acts and those elements may be combined in other ways to accomplish the same objectives. With regard to flowcharts, additional and fewer steps may be taken, and the steps as shown may be combined or further refined to achieve the methods described herein. Acts, elements and features discussed only in connection with one embodiment are not intended to be excluded from a similar role in other embodiments.
As used herein, “plurality” means two or more. As used herein, a “set” of items may include one or more of such items. As used herein, whether in the written description or the claims, the terms “comprising”, “including”, “carrying”, “having”, “containing”, “involving”, and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of”, respectively, are closed or semi-closed transitional phrases with respect to claims. Use of ordinal terms such as “first”, “second”, “third”, etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements. As used herein, “and/or” means that the listed items are alternatives, but the alternatives also include any combination of the listed items.
This patent is a continuation-in-part of application Ser. No. 17/037,295, entitled CONSTRUCTION BLOCK UNITS, filed Sep. 29, 2020, which claims priority from provisional patent application No. 62/968,911, entitled CONSTRUCTION BLOCKS, filed on Jan. 31, 2020, the entire contents of each of which are incorporated herein by reference.
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Number | Date | Country | |
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Parent | 17037295 | Sep 2020 | US |
Child | 17512336 | US |