This disclosure relates to hollow interconnecting prism blocks. More specifically, this disclosure relates to hollow interconnecting prism blocks for use in construction, gardens, flotation, and a variety of other uses.
Presently, hollow interconnecting prism blocks do not have a specific wall thickness with an interior hollow center space inside the hollow interconnecting prism blocks, with the interior hollow center space comprising the same dimensions as the block's outface dimensions, but of a smaller size to account for the wall thickness of the sides of the block, having side center holes in the center area of each side of the hollow interconnecting prism blocks, allowing human hands and/or specialized tools to enter into the interior hollow center space to affix the two blocks together, by manipulating mechanical hardware inside of the interior hollow center space via the connecting holes of the adjacent blocks, whereas the blocks become interconnected together, with the mechanical hardware remaining inside of the interior hollow center space, and have the capability to be affixed together from the parallelogram faces, the top face, and the bottom face, of each block having the same proximate size and shape and same proximate hole patterns, along with being able to pass rebar, pipes, conduit and other materials through the bodies of all the blocks, before, during, or after they are affixed together.
Current hollow interconnecting prism blocks lack the ability to be assembled together while in outer space, while floating on water, or be assembled together while under water, nor can they be physically mounted to existing seawalls and provide sufficient strength and height to prevent rising sea waters from breaching the walls, with the ability to have plumbing pipes, electrical conduit, electrical wires, rebar, and other desired materials installed within the wall structure during and after construction of the desired structure.
With waters continuing to rise, governments and municipalities around the world need to reinforce existing walls, build new walls, and engineer additional solutions to prevent incoming water from destroying waterfront structures and localities.
A major drawback of existing wall systems, is the existing hollow interconnecting prism blocks inability to be joined together on all faces by additional hollow interconnecting prism blocks from within their interior hollow center space and to be securely affixed to another hollow interconnecting prism block or to affixed to an existing structure, by accessing the hollow center space from the side center holes of each of the blocks and by using mechanical hardware to affix the blocks together via their interconnecting holes from within the hollow void areas of the hollow interconnecting prism blocks, nor can existing hollow interconnecting prism blocks be affixed together with hollow connector pipes being glued, fused, or affixed to the inside of their face holes, allowing two or more hollow interconnecting prism blocks to be affixed together, with the ability for pipes, conduit, rebar, wires, or other materials to pass through the structure built with hollow interconnecting prism blocks after the structure has been built, without the need to disassemble the structure, drill holes, nor to modify the structure in any way.
A second major drawback of current hollow interconnecting prism blocks is the inability to pass materials such as rebar, pipes, wire, conduit, etc. through two or more connected hollow interconnecting prism blocks, allowing the materials to enter into the interior hollow center spaces of the hollow interconnected prism blocks, so that the materials can pass through the structure built with hollow interconnecting prism blocks, and can allow materials to pass in different directions throughout the hollow interconnecting prism block structure through the center side holes on each side of the hollow interconnecting prism block.
A third major drawback of existing hollow interconnecting prism blocks is the inability for the interlocking blocks to filled with desired materials and/or strengthening materials to form one continuous and solid structure from all of the hollow interconnecting prism blocks having been previously affixed together with mechanical hardware via the face interconnecting holes or and/or with connector pipes becoming affixed and/or glued to the inside of the face center holes and interconnecting holes of each face of the hollow interconnecting prism blocks, to fulfill a desired purpose, such as to create seawalls, garden wall structures, vertical gardens, floating gardens, other floatation structures, artificial coral reefs, or other desired purposes.
A need exists for improved hollow interconnecting prism blocks to be used for retaining walls, sea walls, foundations, water-capturing garden blocks, vertical gardens, buildings, artificial reefs, and other applications.
Hollow interconnecting prism blocks have at least three parallelogram faces and two ends. The ends of the hollow interconnecting prism blocks are sometimes referred to as bases. In this disclosure the bases may be referred to as a top end or a bottom end, or end faces. In some instances, a hollow interconnecting prism block is said to have four side faces plus the base and top.
The bases could be triangle, square, rectangle, or any number of faces. For example, a pentagonal hollow interconnecting prism block has two pentagonal bases and five rectangular faces. In one aspect, this disclosure provides hollow interconnecting prism blocks comprising at least five faces, wherein comprising at least three or more parallelogram faces, one top base, and one bottom base, a minimum of six vertices and a minimum of nine edges, wherein at least two faces of the hollow interconnecting prism block comprise a face center hole around the center of the face and at least one face connecting hole proximate to each face vertex of each face comprising a face center hole.
In further embodiments, a hollow interconnecting prism block comprises one or more face edge holes proximate to one or more of the face edges.
Yet another aspect of this disclosure is directed to a hollow interconnecting prism block structure, comprising a plurality of hollow interconnecting prism blocks, wherein each hollow interconnecting prism block comprises five or more faces, and wherein each face comprises a center hole and a plurality of interconnecting holes, wherein the plurality of hollow interconnecting prism blocks are connected by hardware via the connecting holes, wherein a plurality of the center holes are aligned whereas connecting holes become aligned.
In yet a further aspect of this disclosure is directed to a hollow interconnecting prism block structure, comprising a plurality of hollow interconnecting prism blocks, wherein each hollow interconnecting prism block comprises five or more faces, and wherein each face comprises a center hole and a plurality of connecting holes, wherein the plurality of hollow interconnecting prism blocks are connected by hollow connector pipes being glued, fused, welded, and or connected to the inside walls of the interconnecting holes and face center holes, wherein a plurality of the center holes are aligned, wherein mechanical hardware may also be used via the connecting holes, for additional securement, while the pipe glued through the face center holes help prevent undesirable materials to enter into interior hollow center spaces of the hollow interconnected prism blocks.
In some embodiments, the hollow interconnecting prism block produces a hollow interconnecting prism block structure, by affixing together hollow interconnecting prism blocks, whereas the hollow interconnecting prism block structure may be filled with a material or a combination of materials, such as self-hardening liquified cementitious materials poured into the face center hole of the top end face of one or more hollow interconnecting prism blocks, to fill the interior hollow center spaces of each and every one of the hollow interconnecting prism blocks, as their face center holes are in proximate alignment, whereas the self-hardening liquified cementitious materials pass through the face center holes to an adjacent and affixed hollow interconnecting prism blocks through the length, width, and height of the structure, with the materials being administered into the block structure encompassing each and every portion of the interior hollow center spaces, until the entire structure has been completely filled in one pour, to produce the strongest possible structure.
This disclosure provides hollow interconnecting prism blocks that can be made of a variety of materials and have a variety of applications. More specifically, this disclosure provides hollow interconnecting prism blocks that can be connected together mechanically on each face of a hollow interconnecting prism block and/or connected together by gluing hollow pipes inside the face center holes and face interconnecting holes.
As used herein, the term “and/or” includes any and all combinations of one or more of the associated items. As used herein, the terms “a”, “an”, and “the” mean one or more, unless contextually or specifically indicated otherwise. As used herein, the term “about” means +/−10% of a stated value. As used herein, the term “end face or end faces” or the term “base or bases” or the term “top side or bottom side” refer to the face or side faces of the hollow interconnecting prism block that may or not be parallelograms. As used herein, the term “blocks” and “block” refer to the hollow interconnecting prism block. As used herein, the term “faces” and “face” refer to the exterior portion of the sides or side of the hollow interconnecting prism block, whereas each face is comprised of an exterior face a wall thickness and an interior face.
As the climate on the Earth continues to change and sea levels continue to rise, stronger and higher retaining walls and seawalls are needed to protect coastal communities. The hollow interconnecting prism block of this disclosure can be used to build stronger and taller retaining walls and seawalls that can be filled with fortifying materials, to produce hollow interconnecting prism block structures, and that can make structures and foundations for earth and vegetation to produce salt marshes and mangroves, watersheds and drainage basins, and gardens for indigenous plants, eatable plants, and/or places for animals to thrive. The design of the hollow interconnecting prism block allows for objects to be passed through the center face holes of the hollow interconnecting prism blocks before filling the hollow interconnecting prism blocks with material(s). For example, metal pipes, plastic pipes, electrical wires, conduit, rebar, insulation, and other materials can be passed through the side face center holes of one or more of the connected hollow interconnecting prism blocks prior to filling the hollow interconnecting prism block structure with fortifying material(s), if desired. Walls created with hollow interconnecting prism blocks manufactured with the aforementioned hollow interconnecting prism block of this disclosure are unlike any other hollow interconnecting prism block in previous existence.
This disclosure provides methods to manufacture hollow interconnecting prism blocks and structures. Each hollow interconnecting prism block has a number of faces that are parallelogram faces, and two end faces also known as the top end face and the bottom end face, whereas the two end faces comprise at least three vertices with face center holes and at least three face interconnecting holes on the faces designed to have holes.
Unlike existing hollow interconnecting prism blocks, any face of the hollow interconnecting prism block with interconnecting holes of this disclosure can be connected to another hollow interconnecting prism block with holes of the same configuration or can be physically mounted to an existing structure. In other words, hollow interconnecting prism blocks of this disclosure can be connected on any parallelogram face or any end face of a hollow interconnecting prism block of the same configuration of holes.
Embodiments of the hollow interconnecting prism blocks have at least two faces that have face center holes and face interconnecting holes.
In some embodiments, the hollow interconnecting prism block has three parallelogram faces (referred to herein as “triangular”) and two end faces. The “end faces” refer to faces of the hollow interconnecting prism block on the top face and bottom face of the block. In other embodiments, the hollow interconnecting prism block has four parallelogram faces (referred to as “rectangular”) and two end faces. In further embodiments, the hollow interconnecting prism block has five parallelogram faces (referred to as “pentagonal”) and two end faces. In additional embodiments, the hollow interconnecting prism block has six parallelogram faces with holes (referred to as “hexagonal”) and two end faces. In still further embodiments, the hollow interconnecting prism block has more than six parallelogram faces and has two end faces, whereas end faces are also known as bases.
Each parallelogram face of a hollow interconnecting prism block comprises four vertices and four edges. One or more faces, and/or end faces of a hollow interconnecting prism blocks comprise a center hole around its center. In some embodiments, the end faces of a hollow interconnecting prism block comprise three or more vertices and three or more edges. In some embodiments, one end face or both end faces of a hollow interconnecting prism block comprise a center hole around its center. In some embodiments, each center hole on a face aligns with the center hole on the opposite face. In some embodiments, one or more connecting holes are located proximate to each vertex of each face. In some embodiments, one or more edge connecting holes are located proximate to the middle of one or more edges of the faces. The orientation and location of the vertex connecting holes and edge connecting holes varies. In some embodiments, the center hole, vertex connecting hole, or edge connecting hole is round. In other embodiments, the center hole, vertex connecting hole, or edge connecting hole is not round.
In some embodiments, all of the faces and end faces of a hollow interconnecting prism block comprise a center hole. In other embodiments, all of the faces and end faces of a hollow interconnecting prism block comprise a center hole and one or more connecting holes. In further embodiments, some faces and/or some end faces have center holes, or connecting holes, or both. In some embodiments, one face or one end face of the hollow interconnecting prism block has no center hole and no connecting holes. In other embodiments, two faces of the hollow interconnecting prism block have no center hole and no connecting holes. In further embodiments, one face and one end face of the hollow interconnecting prism block have no center hole and no connecting holes. In still further embodiments, three faces of the hollow interconnecting prism block have no center hole and no connecting holes. In yet further embodiments, one face and two end faces of the hollow interconnecting prism block have no center hole and no connecting holes. In additional embodiments, two faces and one end face of the hollow interconnecting prism block have no center hole and no connecting holes. In some embodiments, four faces of the hollow interconnecting prism block have no center hole and no connecting holes. In some embodiments, two faces and two end faces of the hollow interconnecting prism block have no center hole and no connecting holes. In some embodiments, three faces and one end face of the hollow interconnecting prism block have no center hole and no connecting holes.
The center holes allow materials to pass through the hollow interconnecting prism block's hollow center space and through the hollow center holes, in different directions, through the center holes on the block to either the hollow center space of an adjacent block though the face center hole or pass to the free air, with the number of possible directions depending on the number of faces that particular hollow interconnecting prism block has. The center holes also allow hollow interconnecting prism blocks to be filled with material(s), or choose to allow the interior of the hollow interconnecting prism blocks to remain hollow. For example, multiple hollow interconnecting prism blocks could be connected together and then filled with sand, concrete, mud, rocks, gravel, water, insulation, gaseous materials, fluids, flotation materials, etc., or the hollow interconnecting prism block would remain with a hollow interior. A structure comprised of plastic materials, with the inside of the wall thickness comprised of foam insulation, may be designed to float on water.
In some embodiments, the surfaces of the faces of a hollow interconnecting prism block are flat and have holes. In some embodiments, the surfaces of the faces of a hollow interconnecting prism block are smooth and have holes. In other embodiments, one or more surfaces of a hollow interconnecting prism block are rough and have holes. In further embodiments, one or more surfaces of a hollow interconnecting prism block comprises a nonslip coating, bumps, ridges, or grooves and have holes.
The hollow interconnecting prism block can be made of any suitable material, depending on the application of the block and the structure being constructed. Strong, consistent materials with a high load carrying ability and resistant to stresses can be used to make the hollow interconnecting prism block. In some embodiments, the hollow interconnecting prism block comprise 6061 aluminum. In certain embodiments, the hollow interconnecting prism block comprise 7050 aluminum. In some embodiments, the hollow interconnecting prism block comprise cement. In certain embodiments, the hollow interconnecting prism block comprise hydraulic cement. In further embodiments, the hollow interconnecting prism block comprise cementitious materials. In some embodiments, the hollow interconnecting prism block comprise glass. In other embodiments, the hollow interconnecting prism block comprise plastic. In certain embodiments, the hollow interconnecting prism block comprise high-density polyethylene (HDPE or No. 2 plastic). In still further embodiments, the hollow interconnecting prism block comprise clear plastic. In additional embodiments, the hollow interconnecting prism block comprise silicone. In additional embodiments, the hollow interconnecting prism block comprise polyvinyl chloride. In further embodiments, the hollow interconnecting prism block comprise metal or alloy. In certain embodiments, the hollow interconnecting prism block comprise aluminum, copper, brass, or stainless steel. In additional embodiments, the hollow interconnecting prism block comprise wood and/or wood products. In some embodiments, the hollow interconnecting prism block comprise cloth. In further embodiments, the hollow interconnecting prism block comprise insulation. In some embodiments, the hollow interconnecting prism block comprise rubber. In some embodiments, the hollow interconnecting prism block comprise flexible rubber. In some embodiments, the hollow interconnecting prism block comprise nitrile. In some embodiments, the hollow interconnecting prism block comprise sponge. In some embodiments, the hollow interconnecting prism block comprise ceramic. In some embodiments, walls or floors or other structures constructed with hollow interconnecting prism block comprising the hollow interconnecting prism block are made of a material and filled with another material. The walls or floors or structures comprising the hollow interconnecting prism block may be filled with air, floatable foam, insulation, or a cementitious material, or another material. In further embodiments, the hollow interconnecting prism block comprise a combination of materials described herein.
The faces of the hollow interconnecting prism block can be thick or thin depending on the application of the block and the structure being manufactured or built. In some embodiments, the face or faces are thin. In other embodiments, the face or faces are thick. In further embodiments, the face or faces have a thickness ranging from about 1 mil to about 12″. In some embodiment, the faces comprise an inner wall and an outer wall. In some embodiments, the faces comprise an inner wall and an outer wall and are hollow in between the inner wall and outer wall. In further embodiments, the faces are filled with a material between the inner wall and outer wall. In still other embodiments, the blocks manufactured with hollow interconnecting prism blocks are partially hollow, so that the only unfilled part of the blocks are the vertex connecting holes, edge connecting holes, center holes, and center hollow space inside of the block.
The size of the holes can have a variety of sizes. The size of holes may vary on each face. The size of the connecting holes may be of a different size of the center hole on the same face or on different faces. Holes of one block may be connected to another block with a separate pipe or pipes that connects between the two blocks.
The hollow interconnecting prism block can have a variety of sizes. In some embodiments, the blocks have edges that are uniform length. In other embodiments, the blocks have one length on the edges of the end faces and a different length along the edges of the parallelogram faces that are not part of the end but are the edges between parallelogram faces.
In some embodiments, the block range in size from about 1 foot to about 20 feet. In other embodiments, the block range in size from about 1 foot to about 15 feet. In further embodiments, the block range in size from about 1 foot to about 10 feet. In still further embodiments, the block range in size from about 1 foot to about 8 feet. In other embodiments, the block range in size from about 1 foot to about 6 feet. In some embodiments, the block range in size from about 1 foot to about 4 feet. In some embodiments, the block range in size from about 1 foot to about 3 feet.
In some embodiments, the hollow interconnecting prism blocks range in size from about 1 inch to about 48 inches. In further embodiments, the hollow interconnecting prism block range in size from about 1 inch to about 36 inches. In still further embodiments, the hollow interconnecting prism block range in size from about 1 inch to about 24 inches. In particular embodiments, the hollow interconnecting prism block range in size from about 1 inch to about 12 inches. In still particular embodiments, the hollow interconnecting prism block range in size from about 250 mils to about 1 inch.
In some embodiments, the edges of the block are about 1 foot long. In some embodiments, the edges of the block are between about 1 and about 2 feet long, inclusive. In further embodiments, the edges of the block are between about 2 and about 3 feet long, inclusive. In still further embodiments, the edges of the block are between about 3 and about 4 feet long, inclusive. In yet further embodiments, the edges of the block are between about 4 and about 5 feet long, inclusive. In certain embodiments, the edges of the block are between about 5 and about 6 feet long, inclusive.
In some embodiments, the edges of the end faces of a block range in size from about 1 inch to about 10 feet and the edges of the parallelogram faces of the block range in size from about 1 inch to about 10 feet.
In some embodiments, a block further comprises a faceplate attached to a face of the block. A faceplate is designed to protect the inside hollow areas of the block and holes from any material entering into the hollow center space interior structure of the hollow interconnecting prism block and its holes, particularly when the block is being prepared to be filled with liquified self-hardening cementitious materials. A faceplate can also be used to be used as part of a form used to produce the desired shape of structure designed for the hollow interconnecting prism block. A faceplate may be designed to cover the center hole, vertex connecting holes, edge connecting holes, or some combination of center hole, vertex connecting holes, edge connecting holes, as well as creating a boundary for materials designed to fill the hollow interconnecting prism block, such that the materials to encapsulate the hollow interconnecting prism block mold used to manufacture a hollow interconnecting block, as the mold is contained within the area formed by the faceplates, to retain the material(s), such as liquified self-hardening cementitious materials within the desired contents of the faceplates.
When a faceplate is attached to a face, designed to provide a seal for the exterior end faces on any face of the block having holes, fortifying materials do not pass through the holes on that face, as desired. When a structure is created from interlocked blocks, faceplates can be attached to a plurality of faces of the hollow interconnecting prism block structure prior to filling the space between the hollow interconnecting prism blocks and the faceplates with a fortifying material.
In some embodiments, a plurality of faceplates is attached to a block or attached to a plurality of blocks. For example, when a wall is created from hollow interconnecting prism blocks, faceplates can be attached to one or more faces of the block. Then, fortifying material can be poured into the center side holes of the wall constructed with the hollow interconnecting prism blocks. The fortifying material will flow inside of the confines of the hollow interconnecting prism block structure, including the hollow center spaces and any face connecting holes and face center holes within the confines established by the faceplates that were mounted to the faces of the blocks. preventing the fortifying material from flowing in undesired directions.
Faceplates can be made of the same material as the hollow interconnecting prism block to which it attaches or of a different material. In various embodiments, faceplates comprise wood, plastic, HDPE, PVC, rubber, nitrile, glass, metal, metal alloy, aluminum, brass, copper, stainless steel, cloth, cementitious materials, ceramic, gasket material, silicone, or combinations thereof.
In some embodiments, the faceplates are adorned with designs or pictures to create an aesthetically pleasing appearance when attached to interlocked block. In certain embodiments, a plurality of faceplates makes up a large design. For example, a large design can be an image of nature, or a city, or a sequence, or an underwater scene, etc. In other embodiments, each faceplate has its own picture, painting, image, or design on it.
This disclosure also provides methods of connecting hollow interconnecting prism blocks. The hollow interconnecting prism blocks of this disclosure are designed to be able to be connected or interconnected, internally from within the hollow center space, at the proximation of where two connecting holes meet from two hollow interconnecting prism blocks placed in alignment with each other. The block can be connected on any of the parallelogram faces or bases that have holes to be connected to, whereas the face center holes on the first block become into alignment with the face center holes on the second block, as the face connecting holes from the first block become into alignment with the face connecting holes of the second block.
This disclosure provides methods for connecting hollow interconnecting prism blocks with hardware. In an embodiment of the method, at least one first connecting hole of a first face of a first hollow interconnecting prism block is aligned with at least one second connecting hole of a second face of a second hollow interconnecting prism block. In some embodiments, the first face of the first hollow interconnecting prism block comprises a first center hole and the second face of the second hollow interconnecting prism block comprises a second center hole, and, during the aligning, the first center hole of the first hollow interconnecting prism block is aligned with the second center hole of the second hollow interconnecting prism block. At least one first connecting hole of the first face of the first hollow interconnecting prism block is connected to the least one second connecting hole of the second face of the second hollow interconnecting prism block with hardware, from inside the hollow center spaces of each of the blocks. The hardware has a designed length to exceed the sum of the lengths of the wall thickness for which the hardware will pass through with a portion of the hardware remaining in the hollow center spaces to allow the ends of the mechanical hardware to be affixed with mechanical hardware which will allow the blocks to be affixed together, whereby enabling the mechanical hardware to be passed through the aligned first face connecting hole and second face hole, so that a portion of the hardware remails in each of the hollow interconnecting prism blocks to ensure connections to the ends of the hardware that remain inside the hollow center spaces of each of the blocks will adjoin the blocks together, which may be accomplished by human hands manipulating the hardware, as first hand enters the center side hole of the first block and the second hand enters the center side hole of the second block and manipulates the mechanical hardware to affix the blocks together.
This disclosure provides methods for connecting hollow interconnecting prism blocks with connection couplings or pipes. In an embodiment of the method, at least one first connecting hole of a first face of a first hollow interconnecting prism block is aligned with at least one second connecting hole of a second face of a second hollow interconnecting prism block. In some embodiments, the first face of the first hollow interconnecting prism block comprises a first center hole and the second face of the second hollow interconnecting prism block comprises a second center outward hole, and, during the aligning, the first center hole of the first hollow interconnecting prism block is aligned with the second center hole of the second hollow interconnecting prism block. At least one first connecting hole of the first face of the first hollow interconnecting prism block is connected to the least one second connecting hole of the second face of the second hollow interconnecting prism block with connection couplings or pipes. The connection couplings or pipes are affixed to the interior of one or more holes of the first hollow interconnecting prism block, as the blocks are in alignment the coupling or pipe becomes affixed to the interior of the one or more holes of the second block.
Any suitable connecting hardware or connecting couplings can be used. The disclosure provides numerous types of hardware that can be used. There are numerous types of connecting couplings and pipes that can be used, such as in various types of materials and design, such as metal pipes and couplings, PVC pipes and couplings, rubber couplings with band clamps, and other various mechanical exterior couplings. Holes of the first block may also be welded together with the hole of the second, from inside of the block's hollow center space. However, the embodiments provided in the disclosure are not meant to be exhaustive of all possible types of hardware, pipe and couplings, or connecting methods that can be used. In some embodiments, the hardware comprises a screw. In some embodiments, the hardware comprises a nail. In some embodiments, the hardware comprises a bolt and a nut. In other embodiments, the hardware comprises threaded rod and a nut. In still other embodiments, the hardware comprises a washer. In further embodiments, the hardware comprises locking inserts which can be inserted into the at least one first connecting hole of the first face of the first hollow interconnecting prism block and into the least one second connecting hole of the second face of the second hollow interconnecting prism block, thereby connecting the two hollow interconnecting prism blocks. In still further embodiments, the hardware comprises mechanical fasteners. In additional embodiments, the hardware comprises grommets. In other embodiments, the hardware comprises inserts, latches, pins, retaining clips, rivets, rivet nuts, socket products, springs, toggle bolts, expandable foam inserts, expandable anchors, concrete anchors, plastic hardware, nuts, washers, and bolts. In some embodiments, the hardware is a combination of any of the hardware described herein, or other suitable hardware.
In some embodiments, the method comprises connecting a plurality of the first connecting holes of the first face of the first hollow interconnecting prism block to a plurality of the second connecting holes of the second face of the second hollow interconnecting prism block. In certain embodiments, the method comprises connecting all of the first connecting holes of the first face of the first hollow interconnecting prism block to all of the second connecting holes of the second face of the second hollow interconnecting prism block. In further embodiments, the method comprises connecting at least one third connecting hole of a third face of the first hollow interconnecting prism block with at least one fourth connecting hole of a fourth face of a third hollow interconnecting prism block.
In some embodiments, the method comprises connecting two hollow interconnecting prism blocks together. In some embodiments, the method comprises connecting more than two hollow interconnecting prism blocks together. In additional embodiments, the method comprises connecting a plurality of blocks in different directions. In further embodiments, the method comprises connecting more than two hollow interconnecting prism blocks together to build a structure. In some embodiments, the structure is a wall, a floor, a foundation, or a building. In other embodiments, the structure is a floatable raft. In further embodiments, the structure is a garden. In still further embodiments, the structure is an artificial reef.
In some embodiments, additional materials are used when connecting the hollow interconnecting prism block. In some embodiments, gaskets are placed between connected hollow interconnecting prism blocks. In some embodiments, fusible links and/or a sealant are placed between connected hollow interconnecting prism block to strengthen the bond between the blocks.
In some embodiments, the hollow interconnecting prism blocks are aligned and fused together by causing plastic coatings on each block to melt and fuse together. In other embodiments, the hollow interconnecting prism block can be aligned and glued together. In still other embodiments, the hollow interconnecting prism block can be welded or brazed together. In some embodiments, the hollow interconnecting prism block are connected together without hardware, but with connector couplings connecting the holes of the hollow interconnecting prism block. A person of ordinary skill in the art can envision additional ways to connect the hollow interconnecting prism block of this disclosure. Such connection methods are envisioned within the scope of this disclosure.
In some embodiments, the method further comprises connecting one or more faceplates to one or more faces of a hollow interconnecting prism block or to one or more faces of one or more interlocked blocks. In such methods, the faceplate is aligned with a face of a hollow interconnecting prism block. Then, the faceplate is attached to cover the center side hole, vertex connecting holes, edge connecting holes, or a combination thereof, of the face with hardware or coupling(s).
In further embodiments, the method comprises filling the interior of the structure comprising hollow interconnecting prism blocks with a fortifying material. In some embodiments, the fortifying material is insulation, foam, sand, water, gravel, rocks, cementitious material, metal reinforcements, or a combination thereof. In some embodiments, the fortifying material is poured, pumped, or otherwise added to flow through the exterior structure of the interlocked block.
The hollow interconnecting prism block can be made through a variety of methods depending on the materials used to make the block. Each hollow interconnecting prism block has at least three parallelogram faces comprising parallelogram faces, a top base comprising a top end face, and bottom face comprising a bottom end face, wherein each face is comprised of a wall thickness of one or more materials, with each face. In some embodiments, the hollow interconnecting prism block are cast poured. In other embodiments, the hollow interconnecting prism block are made from one uniform piece. In some embodiments, the hollow interconnecting prism blocks are made by sewing faces together, gluing faces together, clamping, welding, and/or otherwise connecting the blocks edges together so that the vertices of each of the faces are aligned together with the vertices of an adjacent face. In other embodiments, hollow interconnecting prism blocks are manufactured in one single pour. In other embodiments, hollow interconnecting prism blocks are manufactured from one-piece faces, wherein faces are not manufactured by assembling materials together, whereby the block is manufactured by connecting the faces together to manufacture a block. In other embodiments, hollow interconnecting prism blocks are manufactured by securing a hollow prism block mold with hollow outward protrusions on each designed face into a hollow box with an open top face end, wherein self-hardening cementitious materials are poured into the hollow box encapsulating the hollow prism block mold, wherein the hollow body of the prism block mold and hollow outward protrusions become the hollow void space inside of the hollow interconnecting prism block and the center holes and connecting holes on each designed face.
In some embodiments, particularly where the hollow interconnecting prism block comprise plastic, the hollow interconnecting prism block are manufactured by roto-molding, rotational molding, injection molding, plastic extrusion molding, blow molding, vacuum molding, or by other suitable molding methods. In further embodiments, the hollow interconnecting prism block are constructed from two or more separately constructed components and then joined together. In some embodiments, particularly when the hollow interconnecting prism block comprise metal, the hollow interconnecting prism block are made by bolting the faces together, or welding faces together, or brazing faces together, or machining, casting, forming, joining, or assembling. In additional embodiments, particularly when the hollow interconnecting prism block comprise wood, the hollow interconnecting prism block are made by being machined, assembled, glued together, casted, or as an engineered wood product. In further embodiments, the hollow interconnecting prism block are produced by 3D printing or additive manufacturing, or any process in which material or materials are joined or solidified under computer control to create a three-dimensional object. In some embodiments, rapid prototyping is used to produce the hollow interconnecting prism block.
In some embodiments, the block are made as solid pieces and then desired center holes, connecting holes, or edge holes are drilled and milled, and the interior space is hollowed out for mechanical hardware to be used to pass through the connecting holes, or edge holes. For example, in some embodiments, a solid prism is manufactured and then each face is drilled and milled with the desired configuration of hole locations and then a drill cutting wheel enters into face center hole locations and hollows out the interior portion of the block.
One embodiment of a hollow interconnecting prism block 1000 is shown in
Each parallelogram face 1110 also comprises edges 1510 wherein each parallelogram face 1110 share a union with a second parallelogram face face 1110, whereas the union between each parallelogram face face 1110 and the top end face 1130 share edges 1530, and whereas the union between each parallelogram face face 1110 and the bottom end face 1120 share edges 1520 and edges 1530 share a union with top end face face 1130 and the parallelogram face face 1110, and edges 1520 share a union with bottom end face face 1120 and the parallelogram face face 1110.
Parallelogram face faces 1000 of block 1000 all have the same proximate configuration, size, shape, and dimensions, in
The center hollow space 1810 comprise the interior hollow portion of the block, wherein the center hollow space 1810 shares a union with the interior faces of all interior faces of the block, wherein there are four parallelogram interior faces 1111, one top end interior face 1131, and one bottom end interior face 1121, whereas all six interior faces encapsulate the hollow center space 1810, whereas a hollow interconnecting prism block 1000 having the exterior dimensions of a cube with a proximate 12 inches in length, 12 inches in width, and 12 inches in height, with a uniform wall thickness 1910 of a proximate 1.5 inches, the center hollow space 1810 would be a proximate 8 inches cubed, whereas the volume of center hollow space 1810 of block 1000 would total a proximate 512 cubic inches. Not all interior or exterior faces of each face are shown in
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Each of the six faces 1325 of this 8-inch cuboid hollow interconnecting prism block mold with outward protrusions comprise the same proximate dimensions and the same outward protrusion configurations as each other face 1325, whereas each of the four parallelogram face faces have the same dimensions of 8-inches wide by 8-inches high, whereas the one bottom end face face has the dimensions of 8-inches in length by 8-inches in width, and whereas the one top end face face has the dimensions of 8-inches in length by 8-inches in width, wherein each of the six faces 1325 of the hollow interconnecting block mold of
The hollow block mold of
The hollow block mold of
Block 1000, of
The block mold of
Each outward protrusion of a proximate 2-inches in length from the hollow center space to the outer rims of the protrusions, wherein the outer rims of all the outward protrusions would become flush with the exterior faces of each face of the manufactured block 1000, comprised of a proximate 12-inch cuboid, whereto the block mold of
FIG. G depicts FACE 7131 from
In some embodiments, the interconnecting prism blocks of this disclosure are designed to form a seawall or retaining wall. The holes of each hollow interconnecting prism block when connected together with other hollow interconnecting prism blocks of the same configuration create spaces between the faces of the hollow interconnecting prism block for earth, indigenous vegetation, and/or faceplates, to strengthen the shorelines from erosion. In such embodiments, a plurality of interconnecting prism blocks is interlocked together to form the desired wall of any desired configuration. In certain embodiments, the wall can be made vertical. In other embodiments, the wall is a gravity wall, piling wall, cantilever wall, or an anchored wall. In other embodiments, the hollow interconnecting prism block are arranged to create walls with angles or vertices or curved. In still other embodiments, a wall comprising hollow interconnecting prism block is built at an incline. In some embodiments, the tops and bottoms of the hollow interconnecting prism blocks comprise protrusions and corresponding indentations to receive the protrusions to allow the block to connect at an offset to create an incline. In other embodiments, the shape of the hollow interconnecting prism block enables an incline to be created.
Then, faceplates are attached to the holes of each block on either face of the wall. The faceplates are secured in place so that the designed interiors of the block and/or the interiors between the faceplates and the exterior of the hollow interconnecting prism block can be filled with a desired material. In some embodiments, interiors of the block and/or the interiors between the faceplates and the exterior of the hollow interconnecting prism block wall is filled with sand. In some embodiments, interiors of the block and/or the interiors between the faceplates and the exterior of the hollow interconnecting prism block wall is filled with cement. In other embodiments, the interiors of the block and/or the interiors between the faceplates and the exterior of the hollow interconnecting prism block wall is filled with rocks or gravel. In further embodiments, the interiors of the block and/or the interiors between the faceplates and the exterior of the hollow interconnecting prism block wall is filled with a material of sufficient mass or strength to retain whatever the retaining wall is designed to retain.
Sea walls made from hollow interconnecting prism block promote vegetation and earth to collect within the connected holes of each block, as they are connected together with other block. Two, sandbags made from hollow interconnecting prism blocks with face plates are stronger than typical sandbags due to the block being mechanically connected. Three, the sea wall made of hollow interconnecting prism blocks with face plates attached to the block can be filled with a fortifying material such as cement or sand, thereby increasing the strength of the sea wall. Furthermore, in some embodiments, the hollow interconnecting prism block are made of cloth material with plastic face plates. Such hollow interconnecting prism block can be interlocked and filled with sand between the exterior of the block and the interior of the attached faceplates to provide a superior sandbag-like structure with mechanically connected blocks.
Hollow interconnecting prism blocks intended to be used to create a sea wall can be made of noncorroding materials in order to withstand the corrosive nature of the sea.
In other embodiments, the hollow interconnecting prism blocks of this disclosure are designed to form a foundation for a building or other structure. In such embodiments, a plurality of hollow interconnecting prism blocks is connected in horizontal and vertical fashion according to a design for a foundation. The foundation can have any suitable shape depending on the structure being built. In some embodiments, the connected hollow interconnecting prism block form the foundation with material poured into the structure around the exterior portions of the block. In other embodiments, once the requisite number of hollow interconnecting prism block are connected, faceplates can be added to the interior face and exterior face of the wall created by the interlocked block. Then, a fortifying material can be poured into the interlocked block structure, thereby creating a foundation. Additional structures can be built on top of the foundation.
In other embodiments, the hollow interconnecting prism block of this disclosure are designed to build a structure. The structure could be a residential building, a commercial building, an office building, sports arena, or any building. In some embodiments, the building is a small building such as a garage or shed. In other embodiments, the building is a residential building such as a house. In further embodiments, the building is a large building. The size of the hollow interconnecting prism block used in buildings can vary depending on the size of the building being constructed.
In another embodiment, the interconnecting prism with exterior protrusions of this disclosure are comprised of a buoyant material. In such embodiments, a plurality of interconnecting prism blocks can be interlocked together to create a flotation device. In such embodiments, a plurality of blocks are interlocked together. Then, in some embodiments, faceplates are attached to the face faces of the flotation device that will face the water, thereby preventing water from coming into the flotation device.
The flotation devices comprised of hollow interconnecting prism block can vary in size. In some embodiments, the flotation device is a raft designed to hold one or more people.
Those skilled in the art will recognize, or be able to ascertain, using no more than routine experimentation, numerous equivalents to the specific embodiments described specifically in this disclosure. Such equivalents are intended to be encompassed in the scope of this disclosure and the following claims.
This application claims priority to U.S. Provisional Application No. 63/447,221, filed Feb. 21, 2023 and titled, “HOLLOW INTERCONNECTING BLOCK MOLDS,” and this application also claims priority to U.S. Provisional Application No. 63/436,563, filed Dec. 31, 2022 and titled “Hollow interconnecting prism blocks,” and this application also claims priority to U.S. Non-Provisional application Ser. No. 17/505,876—Docket No. DON. 100CON, filed Oct. 20, 2021, U.S. Non-Provisional application Ser. No. 17/067,619—filed Oct. 9, 2020, U.S. Provisional Application No. 62/912,979, filed Oct. 9, 2019 and titled “Interlocking Blocks molds,” and this application also claims priority to U.S. Non-Provisional application Ser. No. 16/155,990—Docket No. DON. 100UTI, filed Oct. 10, 2018, and International Application No. PCT/US18/55139—Docket No. DON. 100PCT, filed: Oct. 10, 2018, and titled “Interlocking Blocks,” and this application also claims priority to U.S. Provisional Application No. 62/577,917, filed Oct. 27, 2017 and titled “Interlocking Rectangular Prism Blocks Connecting Building Structures” and to U.S. Provisional Application No. 62/577,633, filed Oct. 26, 2017 and titled “Interlocking Trapezoidal Prism Blocks Connecting Building Structures,” all of which applications are incorporated herein by reference in their entireties.