INTERLOCKING CONSTRUCTION BLOCK

BACKGROUND

Construction blocks in their various forms are used throughout the world for the construction of walls and other structures. The use of construction blocks allows structures, such as walls and/or foundations, to be built in traditional masonry style with layers of staggered blocks.

Construction blocks come in many sizes and shapes and go by various names, such as concrete blocks, cinder blocks, breeze blocks, concrete mason units, besser blocks, and others. Construction blocks may be made of various materials, such as one or more of cast concrete, cement with or without cinder, autoclaved aerated concrete, and recycled materials. Construction blocks may come in various sizes. A common construction block has nominal length of about 16 inches, a nominal height of about 8 inches, and varying nominal depth, such as 4 inches, 6 inches, 8 inches, and 12 inches. The actual dimensions are typically about ⅜ inches smaller than the nominal dimensions to account for mortar between the blocks. The construction blocks also typically have a hollow portion in its center or core to reduce weight, improve insulation, and/or provided an interconnected void into which concrete can optionally be poured. The hollow portion is often in the form of one or more holes that extend from the top of the construction block to the bottom. Most commonly, a concrete block is provided with one, two, or three holes.

While conventional construction blocks are useful both the construction and the do-it-yourself industries, they come with certain disadvantages. For example, the stability of a wall made from construction blocks is dependent upon the alignment of the blocks and the use of mortar between the blocks. To properly align a series of blocks and to apply mortar between adjacent blocks or rows of blocks requires time and skill. In the construction industry, time is of paramount importance. In the do-it-yourself industry, skill is often lacking.

There is therefore a need for an improved construction block. There is further a need for a construction block that provides an improvement in construction speed and/or the stability of a constructed structure. There is further a need for a construction block that provides an improvement in construction speed and/or the stability of a constructed structure and that provides flexibility as to its manner of use.

SUMMARY

The present invention satisfies these needs. In one aspect of the invention, an improved construction block is provided.

In another aspect of the invention, a construction block is provided that provides an improvement in construction speed.

In another aspect of the invention, a construction block is provided that provides an improvement in stability of a constructed structure.

In another aspect of the invention, a construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block.

In another aspect of the invention, a construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block, wherein the interlocking mechanism is on the top of the construction block allowing it to interlock with the bottom of another construction block in a manner that helps prevent lateral, longitudinal, and/or rotational movement between the interlocked blocks.

In another aspect of the invention, a construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block, wherein the interlocking mechanism is on the top of the construction block allowing it to interlock with the bottom of another construction block, and wherein a front surface of the construction block has a smooth contour like a conventional construction block.

In another aspect of the invention, a construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block, wherein the interlocking mechanism is on the side of the construction block allowing it to interlock with the side of another construction block in a manner that helps prevent movement between the interlocked blocks.

In another aspect of the invention, a construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block, wherein the interlocking mechanism is on the side of the construction block allowing it to interlock with the side of another construction block in a manner that helps prevent lateral movement between the interlocked blocks.

In another aspect of the invention, a construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block, wherein the interlocking mechanism is on the side of the construction block allowing it to interlock with an interlocking mechanism on the side of another construction block, and wherein the interlocking mechanisms can be engaged with one another by moving the construction blocks towards one another in a longitudinal direction.

In another aspect of the invention, a construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block, wherein the interlocking mechanism is on the side of the construction block allowing it to interlock with the side of another construction block in a manner that helps prevent up and down between the interlocked blocks.

In another aspect of the invention, a construction block system comprises a first construction block and a second construction block, wherein the system includes an interlocking mechanism that allow the first construction block and the second construction block to interlock, wherein the interlocking mechanism is on the top, bottom, left side, and/or right side of the first construction block and/or second construction block.

In another aspect of the invention, a two holed or three-holed construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block.

In another aspect of the invention, a two-holed or three-holed construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block in an overlapping stacked configuration.

In another aspect of the invention, a two holed or three-holed construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block in a stacked, side by side, overlapping, or corner configuration.

In another aspect of the invention, a zero-holed or one-holed construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block.

In another aspect of the invention, a zero-holed or one-holed construction block includes an interlocking mechanism that allows it to interlock with an adjacent construction block in an overlapping stacked configuration.

In another aspect of the invention, a method of constructing a structure using construction blocks comprises interlocking adjacent construction blocks.

In another aspect of the invention, a method of constructing a structure using construction blocks comprises interlocking adjacent construction blocks using mortar.

In another aspect of the invention, a method of constructing a structure using construction blocks comprises interlocking adjacent construction blocks without using mortar.

In another aspect of the invention, a method of constructing a structure using construction blocks comprises interlocking adjacent construction blocks in a manner that provide a gap between the blocks.

In another aspect of the invention, a construction block system comprises a first construction block, the first construction block comprising a top surface, a bottom surface, a front surface, a rear surface, a left surface, and a right surface, wherein a first construction block interlocking mechanism is provided on the top surface of the first construction block; and a second construction block, the second construction block comprising a top surface, a bottom surface, a front surface, a rear surface, a left surface, and a right surface, wherein a second block interlocking mechanism is provided on the bottom surface of the second construction block, wherein the first construction block interlocking mechanism comprises a non-circular recess, wherein the second construction block interlocking mechanism comprises a non-circular protrusion, wherein the non-circular protrusion is receivable within the non-circular recess when the second construction block is positioned on top of the first construction block, wherein the first construction block comprises two or more holes extending from the top surface to the bottom surface and wherein the non-circular recess comprises a pair of longitudinally extending channels that extends from the left side to the right side with a front longitudinally extending channel being on the front side of the two or more holes and with a rear longitudinally extending channel being on the rear side of the two or more holes, wherein the non-circular recess further comprises one or more cross channels that extend from the front longitudinally extending channel to the rear longitudinally extending channel, and wherein the non-circular recess comprises a cross channel that extends between two holes of the two or more holes, a cross channel that extends between the two or more holes and a left side surface, and a cross channel that extends between the two or more holes and a right side surface.

In another aspect of the invention, a construction block system comprises a first construction block, the first construction block comprising a top surface, a bottom surface, a front surface, a rear surface, a left surface, and a right surface, wherein a first construction block interlocking mechanism is provided on the top surface of the first construction block; and a second construction block, the second construction block comprising a top surface, a bottom surface, a front surface, a rear surface, a left surface, and a right surface, wherein a second block interlocking mechanism is provided on the bottom surface of the second construction block, wherein the first construction block interlocking mechanism comprises a non-circular recess, wherein the second construction block interlocking mechanism comprises a non-circular protrusion, wherein the non-circular protrusion is receivable within the non-circular recess when the second construction block is positioned on top of the first construction block, wherein the first construction block comprises two or more holes extending from the top surface to the bottom surface and wherein the non-circular recess comprises a pair of longitudinally extending channels that extends from the left side to the right side with a front longitudinally extending channel being on the front side of the two or more holes and with a rear longitudinally extending channel being on the rear side of the two or more holes, wherein the non-circular recess further comprises one or more cross channels that extend from the front longitudinally extending channel to the rear longitudinally extending channel, wherein the non-circular recess comprises a cross channel that extends between two holes of the two or more holes, a cross channel that extends between the two or more holes and a left side surface, and a cross channel that extends between the two or more holes and a right side surface, wherein the second construction block interlocking mechanism comprises a pair of longitudinally extending ridges that generally correspond to the longitudinally extending channels of the first construction block, wherein the second construction block interlocking mechanism further comprises a plurality of cross ridges, each cross ridge generally corresponding to a cross channel, and wherein one of the areas of the bottom surface of the second construction block that corresponds to the cross channel of the first construction block that extends between the two or more holes and a left side surface has no cross ridge.

In another aspect of the invention, a construction block system comprises a first construction block, the first construction block comprising a top surface, a bottom surface, a front surface, a rear surface, a left surface, and a right surface, wherein a first construction block interlocking mechanism is provided on the top surface of the first construction block; and a second construction block, the second construction block comprising a top surface, a bottom surface, a front surface, a rear surface, a left surface, and a right surface, wherein a second block interlocking mechanism is provided on the bottom surface of the second construction block, wherein the first construction block interlocking mechanism and the second construction block interlocking mechanism engage with one another to provide positional stability between the first construction block and the second construction block when the second construction block is positioned on top of the first construction block, wherein the first construction block front surface and the second construction block front surface are devoid of an interlocking mechanism, wherein the construction block system further comprises a third construction block having a front surface devoid of an interlocking mechanism, wherein the third construction block comprises a third construction block interlocking mechanism on a top surface of the third construction block, wherein the third construction block can be positioned adjacent the first construction block and angled to create a corner, wherein the second construction block is positionable to interlock with both the first construction block and the third construction block, and wherein the front surface of the first construction block and the front surface of the third construction block form a smooth inside corner.

In another aspect of the invention, a method of interlocking construction blocks comprises providing a first construction block, the first construction block comprising a top surface, a bottom surface, a front surface, a rear surface, a left surface, and a right surface, wherein a first construction block interlocking mechanism is provided on the top surface of the first construction block; providing a second construction block, the second construction block comprising a top surface, a bottom surface, a front surface, a rear surface, a left surface, and a right surface, wherein a second block interlocking mechanism is provided on the bottom surface of the second construction block; and stacking the second construction block on top of the first construction block so that the first construction block interlocking mechanism engages the second construction block interlocking mechanism in a manner that provides lateral and rotational stability between the first construction block and the second construction block and that results in a front that is without an interlocking mechanism.

BRIEF DESCRIPTION OF THE DRAWINGS

These features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings which illustrate exemplary features of the invention. However, it is to be understood that each of the features can be used in the invention in general, not merely in the context of the particular drawings, and the invention includes any combination of these features, where:

FIG. 1A is a schematic perspective view from the top of a version of a construction block according to the invention;

FIG. 1B is a schematic perspective view from the bottom of the construction block of FIG. 1A;

FIG. 1C is a schematic top view of the construction block of FIG. 1A;

FIG. 1D is a schematic bottom view of the construction block of FIG. 1A;

FIG. 2A is a schematic perspective view from the top of a system of construction blocks of FIG. 1A in a stacked arrangement;

FIG. 2B is a schematic perspective view from the top of a system of construction blocks of FIG. 1A in an overlapping arrangement;

FIG. 3A is a schematic perspective view from the top of another version of a construction block according to the invention;

FIG. 3B is a schematic perspective view from the bottom of the construction block of FIG. 3A;

FIG. 3C is a schematic top view of the construction block of FIG. 3A;

FIG. 3D is a schematic bottom view of the construction block of FIG. 3A;

FIG. 4 is a schematic perspective view from the top of a system of construction blocks of FIG. 3A in a corner arrangement;

FIG. 5A is a schematic perspective view from the top of another version of a construction block according to the invention;

FIG. 5B is a schematic perspective view from the bottom of the construction block of FIG. 5A;

FIG. 5C is a schematic top view of the construction block of FIG. 5A;

FIG. 5D is a schematic bottom view of the construction block of FIG. 5A;

FIG. 6A is a schematic perspective view from the bottom of another version of a construction block according to the invention;

FIG. 6B is a schematic perspective view from the top of a system of construction blocks of FIG. 6A in an overlapping arrangement;

FIG. 6C is a schematic perspective view from the bottom of another version of a construction block according to the invention;

FIG. 7A is a schematic perspective view from the top of a system of construction blocks of FIG. 6A in a corner arrangement;

FIG. 7B is a schematic perspective view from the top of a system of construction blocks according to another version in a corner arrangement;

FIG. 8A is a schematic perspective view from the top of another version of a construction block according to the invention;

FIG. 8B is a schematic perspective view from the bottom of the construction block of FIG. 8A;

FIG. 8C is a schematic top view of the construction block of FIG. 8A;

FIG. 8D is a schematic bottom view of the construction block of FIG. 8A;

FIG. 9A is a schematic perspective view from the top and left of another version of a construction block according to the invention;

FIG. 9B is a schematic perspective view from the top and right of the construction block of FIG. 9A;

FIG. 9C is a schematic perspective view from the top and left of a system of construction blocks of FIG. 9A in the process of being connected side to side;

FIG. 10A is a schematic perspective view from the top and left of another version of a construction block according to the invention;

FIG. 10B is a schematic perspective view from the top and right of the construction block of FIG. 10A;

FIG. 10C is a partial schematic perspective view from the top and left of another version of a construction block according to the invention;

FIG. 11A is a schematic perspective view from the top of another version of a construction block according to the invention;

FIG. 11B is a schematic perspective view from the bottom of the construction block of FIG. 11A;

FIG. 11C is a schematic top view of the construction block of FIG. 11A;

FIG. 11D is a schematic bottom view of the construction block of FIG. 11A;

FIG. 12A is a schematic perspective view from the top of another version of a construction block according to the invention;

FIG. 12B is a schematic perspective view from the bottom of the construction block of FIG. 12A;

FIG. 12C is a schematic perspective view from the top of a system of construction blocks of FIG. 12A in a stacked arrangement;

FIG. 13A is a schematic perspective view from the top of another version of a construction block according to the invention;

FIG. 13B is a schematic perspective view from the bottom of the construction block of FIG. 13A;

FIG. 14A is a schematic perspective view from the top of a first construction block according to another version of the invention;

FIG. 14B is a schematic perspective view from the bottom of the first construction block of FIG. 14A;

FIG. 14C is a schematic perspective view from the top of a second construction block usable with the first construction block of FIG. 14A;

FIG. 14D is a schematic perspective view from the bottom of the second construction block of FIG. 14C;

FIG. 15A is a schematic perspective view from the top of a first construction block according to another version of the invention;

FIG. 15B is a schematic perspective view from the bottom of the first construction block of FIG. 15A;

FIG. 15C is a schematic perspective view from the top of a second construction block usable with the first construction block of FIG. 15A;

FIG. 15D is a schematic perspective view from the bottom of the second construction block of FIG. 15C;

FIG. 16A is a schematic perspective view from the top of another version of a construction block according to the invention; and

FIG. 16B is a schematic perspective view from the bottom of the construction block of FIG. 14A.

DESCRIPTION

The present invention relates to a construction block with an interlocking mechanism. In particular, the invention relates to a construction block that can interlock with an adjacent construction block in one or more ways. Although the invention is illustrated and described in the context of being useful for construction blocks, the present invention can be useful in other instances. Accordingly, the present invention is not intended to be limited to the examples and embodiments described herein.

FIGS. 1A, 1B, 1C, and 1D show a version of a construction block 100 according to the invention. The construction block 100 is useful, for example, in the construction of one or more of various structures, such as walls, foundations, and the like, and can be used to build the structures in traditional masonry style with layers, rows, and/or columns of stacked and/or staggered blocks. The construction block 100 can take the general form of a concrete block, also known as a cinder block, a breeze block, a concrete mason unit, a besser block, and other names, or can take the general form of a brick or any other block used in the construction industry, and can have a standard size and shape or can have a customized size and shape. The construction block 100 has a body 105 that may be made of conventional material, such as one or more of cast concrete, cement with or without cinder, autoclaved aerated concrete, clay, lime, fly ash, calcium silicate, recycled materials, and the like, or can be made of custom material.

The body 105 of the construction block 100 has a top 110 having a top surface 115, a bottom 120 having a bottom surface 125, a left side 130 having a left side surface 135, a right side 140 having a right side surface 145, and a front 150 with a front surface 151 and a rear 155 with a rear surface 156. The expressions top, bottom, left, right, front, and rear are used for purposes of explanation in the diagrams shown and relate to the orientation of FIGS. 1A and 1B. The expressions can be switched and/or the construction block 100 can be used in any other orientation. The construction block 100 can come in any of various sizes. For example, the body 105 of the construction block 100 may have a nominal length along it longitudinal extent or from the left side 130 to the right side 140 of about 8 inches or 16 inches, a height from top 110 to bottom 120 of about 8 inches, and a depth from front 150 to rear 155 of about 4 inches, about 6 inches, about 8 inches, about 10 inches, or about 12 inches, depending on the desired depth of the structure to be built or other consideration. In a particular version, the construction block 100 has a longitudinal dimension that extends from the left side 130 to the right side 140 that is larger than a transverse dimension that extends from the front 150 to the rear 155 and/or than a height dimension that extends from the top 110 to the bottom 120. These dimensions represent conventional sizes for existing concrete type construction blocks, but any other dimension is possible. The nominal size accounts for the presence of mortar. The actual dimensions of the block without mortar or prior to the application of mortar is 1 and ⅝ inches less. Alternatively, for blocks that are to be used with no mortar, the actual size can be equal to the nominal size. Alternatively, mortar can be used with nominally sized construction blocks 100, as will be explained. The body 105 of the construction block 100 can also optionally contain a hollow portion 160 that extends into and/or through the core of the body 105. The hollow portion 160 can be made up of one or more holes 165 that extend from the top 110 to the bottom 120 of the body 105. In the versions shown in FIGS. 1A, 1B, 1C, and 1D and throughout the application, a hollow portion 160 made up of three holes 165 is shown. However, the construction block 100 of the invention can alternatively have no holes, one hole, two holes, two or more holes, or more than two holes. Alternatively, the construction block 100 may have a nominal size and shape related to conventional bricks, such as by having a nominal size of 3.625 inches by 2.25 inches by 8 inches for a standard brick or any conventional modified or specialized brick size, with the actual and nominal sizes adjustable as discussed above. The brick version can also have any number of holes, including none.

The construction block 100 of the invention is also provided with an interlocking mechanism 170 that allows the construction block 100 to interlockingly engage with another construction block 100 that is to be installed adjacent to the construction block 100. By interlock it is meant that the construction block 100 is able to engage another construction block 100 in a manner where the structures interact with one another in a way that the stability in at least one direction is improved and/or in a way that movement is inhibited in at least one direction relative to a construction block that lacks the interlocking mechanism 170. When construction blocks are interlocked in a structure made of two or more construction blocks 100, adjacent interlocking construction blocks 100 can directly contact one another, can be able to directly contact one another when moved, or can be in close proximity to one another, such as by having an intermediate layer of mortar, air, or the like between the surfaces. The interlocking mechanism 170 may be designed to provide an increase in positional stability and/or inhibition of movement in one, two, three, or more directions, or a combination of directions as will be described.

The interlocking mechanism 170 of the construction block 100 of the version of FIGS. 1A, 1B, 1C, and 1D is a lateral stability mechanism 175. By lateral stability, it is meant that the interlocking mechanism 170 provides improved stability in the lateral direction or front to rear direction between stacked construction blocks 100 than if there was no interlocking mechanism 170. The interlocking mechanism 170 in the version of FIGS. 1A, 1B, 1C, and 1D is provided by a construction block 100 having a top surface 115 and a bottom surface 125 that have cooperating or interlocking structures. For example, as shown, the top surface 115 of the body 105 of the construction block 100 has one or more recesses 180 and the bottom surface 125 has one or more corresponding protrusions 185 that are sized and shaped to correspond and/or fit within the one or more recessed 185 on the top surface 115, such as in a male/female manner with the one or more recesses 180 representing the female part and the one or more protrusions 185 representing the make part. In the particular version shown, the one or more recesses 180 includes a one or more longitudinally extending channels 190 that run at least a portion of the length of the body 105 of the construction block 100. Also in the particular version shown, the one or more protrusions 185 includes one or more outwardly protruding and longitudinally extending ridges 195. In the particular version shown, the one or more recesses 185 comprises a substantially parallel pair of longitudinally extending channels 190 that extend from the left side 130 to the right side 140, and the one or more protrusions 185 comprises a substantially parallel pair of longitudinally extending protrusions 185 that correspond to the pair of longitudinally extending channels. By from the left side to the right side it is meant that the channels and/or protrusions extend to the left or right surfaces or to a point in proximity to the left or right surfaces.

A system 200 of two or more construction blocks 100 is shown in FIG. 2A with the two construction blocks stacked on top of one another. As can be seen the top surface 115 of a first construction block 205 is engaged by the bottom surface 125 of a second construction block 210. The first construction block 205 and the second construction block 205 are interlocked by engagement of a first construction block interlocking mechanism 170 with second construction block interlocking mechanism. In the configuration shown, the one or more longitudinal ridges 195 of the bottom surface 125 of the second construction block 210 is received within the one or more longitudinal channels 190 of the top surface 115 of the first construction block 205 in a male/female relationship, respectively. The cooperating sides of the one or more longitudinal ridges 195 and the one or more longitudinal channels 190 helps to prevent lateral or front to rear movement between the first construction block 205 and the second construction block 210. This inhibition of movement thus provides or increases the lateral stability of the structure being built by the system 200 of construction blocks 100. In addition, by positioning the one or more longitudinal ridges 195 and the one or more longitudinal channels 190 a substantially equal distance from the front 150 and/or the rear 155 of the body 105 of the construction block 100, the alignment of the second construction block 210 relative to the first construction block 205 can be assured or improved. Accordingly, when the one or more longitudinal ridges 195 are received in the one or more longitudinal channels 190, the front 150 of the first construction block 205 and the front 150 of the second construction block 155 will align with one another so that the front surfaces 151 align with one another. The front surface 151 can either be finished or unfinished. The alignment can either be where the two fronts 150 make a substantially flat surface or where there is a predetermined offset, such as when there is to be an inclined wall. This ease in alignment can help speed up the construction process and/or can allow an aligned structure to be constructed by workers with less experience in creating stable structures.

In the particular version of FIG. 2A, the front surface 151 is flat or substantially planar. Alternatively, the front 150 can be differently shaped, such as curved or angled. In the particular version of FIG. 2A, the front surface 151 is substantially smooth. By substantially smooth it is meant that the entire front surface 151 is devoid of an interlocking mechanism and there are no significant recesses or protrusions like the recesses and protrusions on the top and/or bottom surfaces. A substantially smooth surface can still have texture, such as cinder, stone, simulated stone, or the like, as with a conventional construction block, but it lacks noticeable surface features that can be used to interlock with another block. Accordingly, when viewing the construction block 100 from the front, it will appear substantially as a conventional construction block 100, and a wall or the like made of multiple construction blocks 100 with appear from the front substantially as if it were made of conventional construction blocks with a generally smooth overall appearance except for the region between the construction blocks. The rear surface 156 can be the same as the front surface 151 or different. In this version, the construction block 100 having a substantially smooth front surface 151 is provided as a single piece rather than by having the smooth surface being created by the laborious task of adding additional pieces to the surface and/or filling recesses on the surface with mortar or the like.

In one version, such as shown in the version of FIGS. 1A, 1B, 1C, and 1D, the interlocking mechanism 170 is designed in a way that also provides rotational stability 220 between adjacent blocks, such as first construction block 205 and second construction block 210. For example, the recess 180 in the top surface 115 and the protrusion 185 in the bottom surface 125 cooperate in a manner that prevents the first construction block 205 and the second construction block 210 from rotating relative to one another about a vertical axis. The rotational stability 220 can be provided by a plurality of spaced apart engagements or can be provided by the nature of the engagement itself. For example, in the particular version shown, the recess 180 and the protrusion 185 are shaped in a manner that is non-circular with respect to an axis of rotation that is to be stabilized, such as a vertical axis in the version shown. By non-circular it is meant that the interlocking mechanism is of a shape makes it non-rotational about a vertical axis, such as by being circular or at least partially circular. It should be noted that a plurality of circular protrusions or recesses that are spaced along the top surface 115 and/or the bottom surface 125 would not be non-circular, as defined herein, if each is engageable with a separate construction block 100, but circular protrusion or recesses that are spaced apart from front to back and that are designed to each engage one construction block 100 would, collectively, be non-circular, as defined herein. By being non-circular, as defined herein, when the protrusion 185 is received within the recess 180, the engagement prevents rotation. This non-rotational engagement allows rotation to be stabilized without having to provide a plurality of engagements and/or provides additional rotational stability when a plurality of engagements is provided. In addition, by providing a non-rotational recess 180 and protrusion 185, additional lateral stability 175 is provided, particularly when construction blocks are overlapping and/or provided at a corner, as will be further explained below.

FIG. 2B shows a system 200 of three or more construction blocks 100. In this version, the one or more channels 190 of the top surface 115 extend entirely from the left side 130 to the right side 140. In this version, the system 200 allows for overlapping placement of the rows or layers of construction blocks 100 relative to the row or layer they rest on. As can be seen, when a third construction block 215 is placed beside the first construction block 205 so that the left side 130 of the third construction block 215 engages the right side 140 of the first construction block 205 in a manner where the one or more channels 190 of the first construction block 205 generally align with the one or more channels 190 of the third construction block 215 effectively creating one long channel. When the second construction block 210 is then placed atop the first construction block 205 and the third construction block 215 in an overlapping configuration as shown, the longitudinal ridge 195 will be received partly in the longitudinal channel 190 of the first construction block 205 and partly in the longitudinal channel 190 of the third construction block 215. In this version, not only does the interlocking mechanism 170 provide lateral stability and proper alignment of the second construction block 210 relative to the first construction block 205 below it, but it also provides lateral stability and proper alignment of the first construction block 205 relative to the third construction block 215 positioned beside it by nature of the bottom surface 125 of the second construction block 210. As alluded to above, the lateral stability 175 of overlapping construction blocks 100 can be further increased by providing a recess 180 and protrusion 185 that are non-rotational with respect to one another, such as by being non-circular. If, for example, a single circular engagement were to be provided between the first construction block 205 and the second construction block 210 and a single circular engagement were to be provided between the third construction block 215 and the second construction block 210, the second construction block 210 would not help to stabilize the lateral stability between the first construction block 205 and the third construction block 215 because of the rotatability between the engagements.

FIGS. 3A, 3B, 3C, and 3D show another version of a construction block 100 of the invention. This version is similar to the version of FIGS. 1A, 1B, 1C, and 1D except that the one or more recesses 180 of the interlocking mechanism 170 on the top surface 115 of the body 105 includes one or more cross channels 305. By cross channels it is meant channels that channels that run in a direction other than, such as substantially perpendicular to, the longitudinal channels 190. In the version of FIGS. 3A, 3B, 3C, and 3D, where three holes 165 are provided, there are four cross channels 305 provided. In a two-hole version, there would be three cross channels 305 and in a one-hole version there would be two cross channels 305.

In one particular version in accordance with FIGS. 3A, 3B, 3C, and 3D, and as shown in FIG. 4, the cross channels 305 are positioned so as to allow a system 200 of construction blocks 100 to be positioned in a corner configuration to thus provide corner stability 400 in addition to lateral stability 175. By corner stability it is meant any contact or potential contact between adjacent construction blocks 100 at the corner of a structure made up of the construction blocks 100 that helps to prevent sliding between the adjacent blocks that would result in misalignment of the corner of the structure. In this particular version, the cross-channels 305 are perpendicular to the longitudinal channels 190 and are spaced to correspond to the one or more longitudinal ridges 195 on the bottom surface 125 of the construction block 100. By this arrangement and as can be seen in FIG. 4, a first construction block 405 of the type shown in FIG. 3A can be placed at an angle with respect to a second construction block 410, such as by placing them where their respective longitudinal axes are perpendicular. When the second construction block 410 is placed as shown in FIG. 4, the one or more cross channels 305 of the second construction block 410 are aligned with the one or more longitudinal channels 190 of the first construction block 405. Then, when a third construction block 415 is placed atop the first construction block 405 and the second construction block 410, the third construction block 415 can overlap the other construction blocks with a portion of the one or more longitudinal ridges 195 of the third construction block 415 being received in a longitudinal channel 190 of the first construction block 405 and a portion being received in a cross channel 305 of the second construction block 410. As can also be seen in FIG. 4, because of the smooth nature provided by there not being an interlocking mechanism on the front surfaces 151 of the first construction block 405 and the third construction block 415, an inside corner 420 can be created that is also smooth.

The arrangement of FIG. 4 provides lateral stability 175 and corner stability 400 among the blocks. In addition, by properly positioning the interlocking mechanism 170 on the surfaces, the alignment of third construction block 415 with respect to the first construction block 405 can be assured or facilitated, and in addition the alignment of the rear 155 of the third construction block 415 with respect to the right side 140 of the second construction block 410 can be assured or facilitate. In so doing, the alignment of the right side 140 of the second construction block 410 and the rear 155 of the first construction block 405 is also assured or facilitated. Furthermore, as alluded to above, the corner stability 400 of overlapping construction blocks 100 can be further increased by providing a recess 180 and protrusion 185 that are non-rotational with respect to one another, such as by being non-circular. If, for example, a single circular engagement were to be provided between the first construction block 405 and the third construction block 415 and a single circular engagement were to be provided between the second construction block 410 and the third construction block 415, the third construction block 415 would not help to stabilize the corner stability 400 between the first construction block 405 and the second construction block 410 because of the rotatability between the engagements.

Another version of a construction block 100 according to the invention is shown in FIGS. 5A, 5B, 5C, and 5D. In this version, the interlocking mechanism 170 in addition to providing lateral stability 175 also provides longitudinal stability 500. By longitudinal stability it is meant stability in the longitudinal direction when two or more construction blocks 100 are stacked on top of one another in that the stacked blocked are inhibited from moving longitudinally or left and right relative to each other. In this version, the top surface 115 of the body 105 includes one or more cross channels 305 such as those described above in connection with FIG. 3A. The bottom surface 125 in addition to the longitudinal ridges 195 is provided with one or more cross ridges 505 that correspond to the one or more cross channels 305. When two construction blocks 100 according to this version are stacked on top of one another, the one or more longitudinal ridges 195 on the bottom surface 125 of one construction block 100 will be received in the one or more longitudinal channels 190 on the top surface 115 of the other construction block 100, and the one or more cross ridges 505 will be received in the one or more cross channels 305. This combination provides both lateral and longitudinal stability and alignment. In the particular version shown in FIGS. 5A, 5B, 5C, and 5D, the combination of longitudinal channels 190 and cross channels 305 create a generally rectangular shaped interlocking mechanism 510, which can be substantially square or an elongated rectangle. When one or more holes 165 are provided, the rectangular shaped interlocking mechanism 510 can surround one hole 165 or multiple holes 165, or multiple rectangular shaped interlocking mechanisms 510 can be provided with each surrounding a different hole 165. In another version, the rectangular shape can be replaced by another shape, such as a non-circular shape.

FIG. 6A shows a variation on the version of FIGS. 5A, 5B, 5C, and 5D that allows for overlapped stacking of a system 200 of construction blocks 100 as shown in FIG. 6B. In this version, the bottom surface 125 near the right side 140 has a surface 605 that has no protrusion or cross ridge. Without this surface 605 that has no protrusion or cross ridge, a cross ridge 305 would not fit within the cross channel 305 when used in an overlapping configuration as shown in FIG. 6B. FIG. 6C shows a version similar to FIG. 6A but with both ends having a surface 605 that has no protrusion or cross ridge. This version allows for more convenient and faster construction since a person stacking the construction blocks does not have to check the orientation of the block to make sure the surface 605 that has no protrusion or cross ridge is on the correct side. The one end surface 605 that has no protrusion or cross ridge also allows the version of FIG. 6A or 6C to be used in a corner configuration 400, as shown in FIG. 7A. Another version with two surfaces 605 that are cross surfaces that have no protrusion is shown in FIG. 7B. With this version, the construction block 100 can be used in a corner configuration 400 in a manner that does not result in a gap in the corner.

FIGS. 8A, 8B, 8C, and 8D show another version of a construction block 100 that has an interlocking mechanism 170 provides lateral stability 175 and longitudinal stability 500 and that has not limitations when it comes to overlapping or corner configurations. With this version, the interlocking mechanism 170 is a center located interlocking mechanism 800 that does not extend to the ends of the construction block 100. For example, in the version shown in FIGS. 8A, 8B, 8C, and 8D, the center located interlocking mechanism 800 extends at least partially around a center hole 165 in a three-hole construction block 100 with one or more longitudinal channels 190 and one or more cross channels 305 that correspond to one or more longitudinally extending ridges 195 and one or more cross ridges 500. In a two-hole construction block 100 the interlocking mechanism 170 can comprise or consist of a single cross channel 305 and cross ridge 500 between the two holes and one or more longitudinally extending channels 190 and one or more longitudinally extending ridges 195 that are near the center of the construction block 100. For example, in this version the interlocking mechanism 170 can be I-shaped.

Another version of a construction block 100 according to the invention is shown in FIGS. 9A, 9B, and 9C. In this version, the interlocking mechanism 170 in addition to providing lateral stability 175 and/or longitudinal stability 500 along the top 110 and bottom 120, the interlocking mechanism 170 also includes a side interlocking mechanism 900 that allows the left side 130 of the construction block 100 to interlockingly engage the right side 140 of the construction block 100. In the version shown, the side interlocking mechanism 900 comprises one or more side recesses 905 on the right side surface 145 that receive one or more side protrusions 910 on the left side surface 135. For example, the one or more side recesses 905 can comprise one or more vertical channels 915, and the one or more side protrusions 910 can comprise one or more vertical ridges 920 that correspond to the one or more vertical channels 915. FIG. 9C shows a system 200 of two construction blocks 100 according to this version of the invention placed beside one another. When the first construction block 205 and the other construction block 215 are then moved toward one another, the side interlocking mechanism 900 engages in that the one or more protrusions 910 on the left side 130 will be received within the one or more recesses 905 on the right side 140 of the construction blocks 100. The engagement of the side locking mechanism 900 by moving the construction blocks towards one another is advantageous in that it allows for faster installation than if a slot has to be slid into from the top or bottom, and it also allows easier installation in tight spaces, for example where there is not much space above a row of construction blocks because of a ceiling or other structure. In an alternative version, the side interlocking mechanism 900 can be provided without any interlocking mechanism on the top 115 or bottom 120 of the construction block 100 or can be provided with any of the other interlocking mechanisms 170 discussed herein.

The side interlocking mechanism 900 can also be designed to provide height stability 925. For example, the side interlocking mechanism 900 can include one or more side protrusions 910 that are received within one or more side recesses 905 in a manner that inhibits or reduces the amount of up and down movement between adjacent construction blocks 100. One version of a side interlocking mechanism 900 that provide height stability 925 is shown in FIGS. 10A and 10B. As can be seen, this version provides one or more side cross ridges 930 and one or more side cross channels 935 that receive the one or more side cross ridges 930. Another version is shown in FIG. 10C where a diagonally extending ridge 940 can be received in a corresponding diagonally extending channel to provide both height stability 925 and lateral stability 175. Alternatively, multiple diagonally extending ridges 940 can be provided, which can be either parallel, can cross to form an X-shape, or can be otherwise positioned on the side surfaces. Alternatively, the one or more side protrusions 910 and one or more side recesses 905 can take on any other geometric shape, such as a circle, oval, ovoid, square, rectangle, triangle, pentagon, other polygonal, a cross-shape, an I-shape, an H-shape, bars, arrows, and the like, and any combination and quantity of these shapes. These shapes can also be used on the top 110 and/or bottom 120 of the construction block 100. As with the versions of FIGS. 9A, 9B, and 9C, the version of FIGS. 10A and 10B and the version of FIG. 10C can be used in conjunction with any of the interlocking mechanisms 175 described herein or with no interlocking mechanism on the top 110 or bottom 120 of the construction block 100.

FIGS. 11A, 11B, 11C, and 11D show another version of the construction block 100 of the invention similar to the version of FIGS. 5A, 5B, 5C, and 5D. In the version of FIGS. 5A, 5B, 5C, and 5D, the one or more longitudinal channels 190 and/or the one or more cross channels 305 are generally U-shaped. However, the channels can take any other cross-sectional shape. For example, in the version of FIGS. 11A, 11B, 11C, and 11D, the one or more longitudinal channels 190 and/or the one or more cross channels 305 are generally L-shaped and extend to the edges of the construction block 100. Alternatively, the channels can take any other shape, such as V-shaped, elongated U-shaped, or included rounded portions or be a combination of these or other shapes. Correspondingly, the one or more longitudinally extending ridges 195 and/or the one or more cross ridges 505 can be shaped to correspond to the shape of the one or more longitudinal channels 190 and/or the one or more cross channels 305, such as by extended to the edge of the construction block 100 as shown in the version of FIGS. 11A, 11B, 11C, and 11D. Optionally, the one or more longitudinal channels 190 and/or the one or more cross channels 305 can be reinforced with rebar or otherwise strengthened. Optionally, the one or more longitudinal ridges 195 and/or the one or more cross ridges 505 can be reinforced with rebar or otherwise strengthened. Similarly, the one or more side recesses 905 and/or one or more side protrusions 910 can be reinforced with rebar.

Another version of the construction block 100 of the invention is shown in FIGS. 12A, 12B, and 12C. This version is similar to the version of FIGS. 1A, 1B, 1C, and 1D, but demonstrates that the height of the one or more protrusions 185, such as the one or more longitudinally extending ridges 195, can be selected to be the same as or different than the depth of the one or more recesses 180, such as the one or more longitudinally extending channels 190. In the version of FIGS. 1A, 1B, 1C, and 1D, the height of the one or more protrusions 185 and the depth of the one or more recesses 180 is substantially the same. The version of FIGS. 1A, 1B, 1C, and 1D can be used with or without mortar. When used without mortar, the blocks 100 lie adjacent or atop one another with little or no space there between. In the version of FIGS. 12A, 12B, and 12C, the height of the one or more protrusions 185 is greater than the depth of the one or more recesses 180. In this version, a gap 950 can be provided between the bottom surface 125 of one construction block 100 and the top surface 115 of a construction block 100 beneath it and/or between the right surface 135 and the left surface 145 of a construction block 100 and another construction block adjacent to it. The gap 950 can be provided for aesthetic reasons and/or to allow mortar or the like to be inserted into the gap 950. The gap can be any desired height, such as from about one-half inch to about 2 or more inches, and in one particular version is about 1⅝ inches. Alternatively, the height of the one or more protrusions 185 can be less than the depth of the one or more recesses 180 to provide space within the one or more recesses 180 for mortar or air. In one particular version, the construction block 100 can be an actual nominal size and the depth of the recesses can be sufficient that mortar can be used in the recesses while maintaining the nominal size. Though the version of FIGS. 12A, 12B, and 12C is shown in connection with the interlock mechanism 170 of the version of FIGS. 1A, 1B, 1C, and 1D, it can be applied to any of the interlocking mechanisms discloses herein.

FIGS. 13A and 13B show a two-hole version of a construction block 100 according to the invention. The version shown is similar to the FIG. 6A version discussed above, but any of the locking mechanisms 175 disclosed, whether on the top 110 and 120 or on the left side 130 and right side 140 can be applied to a two-hole or any other number of hole version of a construction block 100.

FIGS. 14A, 14B, 14C, and 14D show another version of the invention. In this version a first construction block 1010 is provided that has one or more recesses 180 provided on one or more of its sides, including one or more of the top 110, the bottom 120, the left side 130, and the right side 140. In the particular version shown, one or more recesses 180 are provide on the top 110 while no recesses or protrusions are provided on the bottom 120. A second construction block 1020 is provided that has one or more protrusions 185 provided on one or more of its sides, including one or more of the top 110, the bottom 120, the left side 130, and the right side 140. In the particular version shown, one or more protrusions 185 are provide on the bottom 120 while no recesses or protrusions are provided on the top 110. The interlocking mechanism 175 in this version is engaged when the second construction block 1020 is placed atop the first construction block 1010. This version is useful in many situations, such as when it is desirable to have a flat surface on the bottom or top of a wall or other structure. This version can also be used in conjunction with another version, such as the version shown in FIGS. 13A and 13B. For example, a row of first construction blocks can serve as a bottom layer of a wall. Then layers of construction blocks 100 according to FIGS. 13A and 13B or any other version can then form layers of the wall and can be topped off with a row of second construction blocks 1020. Similarly, a construction block 100 with one or recesses on the left side 130 or right side 140 can be used with a construction block 100 with one or more protrusion on the opposite side. Alternatively, a wall or other structure can be made from first construction blocks 1010 atop one another with mortar being used to connect the surfaces and with the recesses 180 allowing for a better grip of the mortar.

FIGS. 15A, 15B, 15C, and 15D show another version like that of FIGS. 14A, 14B, 14C, and 14D with a first construction block 1010 and a second construction block 1020 that can be used together. In this version the first construction block 1010 is provided with one or more recesses 180 on both the top 110 and the bottom 120, on both the left 130 and the right 140, or on all four side, as shown in Figures. The second construction block 1020 is provided with one or more protrusions 185 provided on the top 110 and the bottom 120, on the left side 130 and the right side 140, or on all four sides as shown in the Figures. The interlocking mechanism 175 in this version is engaged when the second construction block 1020 is placed atop, below, or adjacent the first construction block 1010. This version can be used in alternating layers of a wall or other structure or in any other manner. Alternatively, a wall or other structure can be made from first construction blocks 1010 atop or adjacent to another first construction block 1010 with mortar being used to connect the surfaces and with the recesses 180 allowing for a better grip of the mortar, optionally with rebar reinforcement.

FIGS. 16A and 16B show a zero-hole version of a construction block 100 according to the invention. The version shown is similar to the FIG. 6A version discussed above, but any of the locking mechanisms 175 disclosed, whether on the top 110 and 120 or on the left side 130 and right side 140 can be applied to a zero-hole or any other number of hole version of a construction block 100.

The various versions of construction blocks 100 discussed above offer several advantages over convention construction blocks including the advantages discussed above and additional advantages. For example, in addition to aiding in stability and/or alignment, the construction block 100 of the invention allows for the use or no mortar and for the use of less mortar when mortar is used. In addition, once the construction blocks 100 are pressed together, the one or more recesses 180 can be an escape for excess mortar, such as by escaping through the channels shown near the center of FIG. 6B and similarly elsewhere. A small amount of the excess can be allowed to serve as a grip for an applied application to the construction block 100, such as additional mortar or texture. Also, once the construction blocks 100 are pressed together, mortar can be removed from the edge of the one or more recesses 180, such as the recesses shown near the center of FIG. 6B, so the small hole can be later used for better grip of an applied application such as mortar or texture or the like. If not using mortar, the edges of the one or more recesses 180 can be used for providing a grip for the later application of mortar or texture or the like.

Although the present invention has been described in considerable detail with regard to certain preferred versions thereof, other versions are possible, and alterations, permutations and equivalents of the versions shown will become apparent to those skilled in the art upon a reading of the specification and study of the drawings. For example, the cooperating components may be reversed or provided in additional or fewer number, and all directional limitations, such as up and down and the like, can be switched, reversed, or changed as long as doing so is not prohibited by the language herein with regard to a particular version of the invention. Like numerals represent like parts from figure to figure. When the same reference number has been used in multiple figures, the discussion associated with that reference number in one figure is intended to be applicable to the additional figure(s) in which it is used, so long as doing so is not prohibited by explicit language with reference to one of the figures. Also, the various features of the versions herein can be combined in various ways to provide additional versions of the present invention. Furthermore, certain terminology has been used for the purposes of descriptive clarity, and not to limit the present invention. Throughout this specification and any claims appended hereto, unless the context makes it clear otherwise, the term “comprise” and its variations such as “comprises” and “comprising” should be understood to imply the inclusion of a stated element, limitation, or step but not the exclusion of any other elements, limitations, or steps. Throughout this specification and any claims appended hereto, unless the context makes it clear otherwise, the term “consisting of” and “consisting essentially of” should be understood to imply the inclusion of a stated element, limitation, or step and the exclusion of any other elements, limitations, or steps or the exclusion of any other essential elements, limitations, or steps, respectively. Throughout the specification, any discussion of a combination of elements, limitations, or steps should be understood to include (i) each element, limitation, or step of the combination alone, (ii) each element, limitation, or step of the combination with any one or more other element, limitation, or step of the combination, (iii) an inclusion of additional elements, limitations, or steps (i.e. the combination may comprise one or more additional elements, limitations, or steps), and/or (iv) an exclusion of additional elements, limitations, or steps or an exclusion of essential additional elements, limitations, or steps (i.e. the combination may consist of or consist essentially of the disclosed combination or parts of the combination). All numerical values, unless otherwise made clear in the disclosure or prosecution, include either the exact value or approximations in the vicinity of the stated numerical values, such as for example about +/− ten percent or as would be recognized by a person or ordinary skill in the art in the disclosed context. The same is true for the use of the terms such as about, substantially, and the like. Also, for any numerical ranges given, unless otherwise made clear in the disclosure, during prosecution, or by being explicitly set forth in a claim, the ranges include either the exact range or approximations in the vicinity of the values at one or both of the ends of the range. When multiple ranges are provided, the disclosed ranges are intended to include any combinations of ends of the ranges with one another and including zero and infinity as possible ends of the ranges. Therefore, any appended or later filed claims should not be limited to the description of the preferred versions contained herein and should include all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention.

INTERLOCKING CONSTRUCTION BLOCK

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CPC

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