Interlocking composite construction block

Abstract

Embodiments relate to an enhanced method for building walls by primarily reducing the time for assembly. The design is for a molded multi-segment plastic composite construction block that interlocks horizontally, vertically and orthogonally with a clearance-fit, does not require mortar for structural integrity and is self-aligning. The blocks are molded out of natural-fiber reinforced thermoplastic composites with thermal expansion coefficient less than 0.0002 per degree Celsius and compression strength greater than 60 MPa.

Claims

1. A segmented thermoplastic composite construction block comprising: a plurality of segments, each segment having a segment length, a segment width equal to the segment length, a first open end, a second open end opposite the first open end, and a hollow interior; interlocking features located at the first and second open ends of each segment, wherein the block is configured to interlock with adjacent blocks horizontally, vertically, and orthogonally, wherein the interlocking features of each segment comprises a lip and an inset, the lip formed at and surrounding a perimeter of the first open end, the inset formed at and surrounding a perimeter of the second open end, the lip and inset configured to provide a clearance fit with corresponding features on adjacent blocks; and wherein the lip includes a first hole and a second hole, the first and second holes arranged on opposite sides of the lip and facing one another, the first and second holes configured to allow a first reinforcement element to be inserted through the opposite sides of the lip and the hollow interior; and wherein the inset includes a first hole and a second hole, the first and second holes of the inset arranged on opposite sides of the inset and facing one another, the first and second holes of the inset configured to allow a second reinforcement element to be inserted through the opposite sides of the inset and the hollow interior.

2. The segmented thermoplastic composite construction block of claim 1, wherein each segment includes vertically oriented channels capable of aligning with a vertically oriented channel of an adjacent interlocking block configured to receive rebar or other reinforcements.

3. The segmented thermoplastic composite construction block of claim 1, wherein the segmented thermoplastic composite construction block comprises polyethylene.

4. The segmented thermoplastic composite construction block of claim 1, wherein the segmented thermoplastic composite construction block comprises cross-linked polyethylene.

5. The segmented thermoplastic composite construction block of claim 1, wherein the segmented thermoplastic composite construction block comprises polypropylene.

6. The segmented thermoplastic composite construction block of claim 1, wherein the segmented thermoplastic composite construction block comprises hemp fiber.

7. The segmented thermoplastic composite construction block of claim 1, wherein the segmented thermoplastic composite construction block comprises wood fiber derived from pulp mill waste.

8. The segmented thermoplastic composite construction block of claim 1, wherein the segmented thermoplastic composite construction block comprises rice hulls.

9. An assembly comprising the segmented thermoplastic composite construction block of claim 1 and said first and second reinforcement elements, wherein each of said first and second reinforcement elements comprises rebar.

10. An assembly comprising: a first composite construction block including a first segment comprising: a plurality of walls, a first open end, a second open end, and a hollow interior; a lip formed along and surrounding a perimeter of the first open end; and a first hole and a second hole, the first and second holes extending through opposite sides of the lip and facing one another; and a second composite construction block configured to be stacked atop a portion of the first composite construction block, the second composite construction block including a second segment comprising: a plurality of walls, a first open end, a second open end, and a hollow interior; an inset formed along interior surfaces of the plurality of walls at the second open end of the second segment and surrounding a perimeter of the second open end of the second segment; and a first hole and a second hole, the first and second holes of the second segment extending through opposite sides of the inset and facing one another; wherein, when the second composite construction block is stacked atop the portion of the first composite construction block, the lip is arranged within the inset and the first and second holes of the first and second segments align with one another to allow a reinforcement element to be inserted through the lip, the inset, and the hollow interiors of the first and second segments of the first and second composite construction blocks.

11. The assembly of claim 10, wherein the lip is configured to fit within the inset via a clearance fit.

12. The assembly of claim 10, wherein the lip and inset are sized and shaped to allow removable engagement of the lip within the inset.

13. The assembly of claim 10, wherein the lip comprises a length and a uniform thickness along an entirety of the length of the lip, and wherein the inset comprises a length and a uniform depth along an entirety of the length of the inset.

14. The assembly of claim 10, wherein the first and second composite construction blocks are configured such that, when the lip is arranged within the inset: the first hole of the first composite construction block is arranged adjacent to the first hole of the second composite construction block; and the second hole of the first composite construction block is arranged adjacent to the second hole of the second composite construction block.

15. A composite construction block comprising at least one segment, the at least one segment comprising: a plurality of walls connected to one another, a first open end, a second open end opposite the first open end, and a hollow interior; a lip formed along and surrounding a perimeter of the first open end; an inset formed along interior surfaces of the plurality of walls at the second open end and surrounding a perimeter of the second open end; a first hole and a second hole, the first and second holes extending through opposite sides of the lip and arranged to face one another, the first and second holes configured to allow a first reinforcement element to be inserted through the opposite sides of the lip and the hollow interior; and a third hole and a fourth hole, the third and fourth holes extending through opposite sides of the inset and arranged to face one another, the third and fourth holes configured to allow a second reinforcement element to be inserted through the opposite sides of the inset and the hollow interior.

16. The composite construction block of claim 15, wherein said first and second holes are coaxially aligned about a first axis and wherein said third and fourth holes are coaxially aligned about a second axis that is parallel to the first axis.

17. The composite construction block of claim 15, wherein the lip comprises a length and a uniform thickness along an entirety of the length of the lip, and wherein the inset comprises a length and a uniform depth along an entirety of the length of the inset.

18. An assembly comprising: a first composite construction block comprising: a first segment comprising a first open end, a second open end, a hollow interior, a lip extending along and surrounding a perimeter of the first open end, and a first pair of holes located in the lip and facing one another; and a second segment comprising a first open end, a second open end, a hollow interior, a lip extending along and surrounding a perimeter of the first open end of the second segment, and a second pair of holes located in the lip of the second segment and facing one another; a second composite construction block configured to be stacked atop a first portion of the first composite construction block, the second composite construction block comprising: a third segment comprising a first open end, a second open end, a hollow interior, an inset formed at and surrounding a perimeter of the second open end of the third segment, and a third pair of holes located in the inset and facing one another, wherein the inset is configured to receive the lip of the first segment; and a third composite construction block configured to be stacked atop a second portion of the first composite construction block, the third composite construction block comprising: a fourth segment comprising a first open end, a second open end, a hollow interior, an inset formed at and surrounding a perimeter of the second open end of the fourth segment, and a fourth pair of holes located in the inset of the fourth segment and facing one another, wherein the inset of the fourth segment is configured to receive the lip of the second segment; and wherein, when the second and third composite construction blocks are stacked atop the first and second portions of the first composite construction block, the lips of the first and second segments are arranged within the insets of the third and fourth segments and the first, second, third, and fourth pair of holes align with one another and are configured to allow a reinforcement element to be inserted through the lips and insets to inhibit separation of the first, second, and third composite construction blocks from one another.

19. The assembly of claim 18, wherein the lips of the first and second segments of the first composite construction block are separated from one another by a gap that is sized to receive a portion of a wall of the second composite construction block and a portion of a wall of the third composite construction block.

20. The assembly of claim 18, wherein: the lip of the first segment comprises a length and a uniform thickness along an entirety of the length of the lip of the first segment; the lip of the second segment comprises a length and a uniform thickness along an entirety of the length of the lip of the second segment; the inset of the third segment comprises a length and a uniform depth along an entirety of the length of the inset of the third segment; and the inset of the fourth segment comprises a length and a uniform depth along an entirety of the length of the inset of the fourth segment.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 discloses the appearance of a typical CMU as per illustrative embodiments of the invention.

(2) FIG. 2 discloses a single multi-segment block as per illustrative embodiments of the invention.

(3) FIG. 3 discloses a single block segment with interlocking male lip around the segment perimeter as per illustrative embodiments of the invention.

(4) FIG. 4 discloses a single block segment with interlocking female inset around the segment perimeter as per illustrative embodiments of the invention.

(5) FIG. 5 discloses details of an interlocking male lip and female inset in an assembled wall segment wall as per illustrative embodiments of the invention.

(6) FIG. 6 discloses the two offset interlocking 3-segment blocks as per illustrative embodiments of the invention.

(7) FIG. 7 discloses two orthogonally interlocking 3-segment blocks forming a corner as per illustrative embodiments of the invention.

(8) FIG. 8 discloses the two offset interlocking 3-segment blocks with single segment block to terminate a wall as per illustrative embodiments of the invention.

(9) FIG. 9 discloses a single segment block with a protrusion on an end face for locating windows or doors as per illustrative embodiments of the invention.

(10) FIG. 10 discloses the chamfers on the exposed face of a block as per illustrative embodiments of the invention.

DETAILED DESCRIPTION

(11) Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.

(12) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting the invention. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms a, an, and the are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

(13) The use of the term horizontal is intended to mean the direction along the length of a wall. The use of the term vertical is intended to mean the direction perpendicular to the base plane of the installation, typically the ground. The use of the term orthogonal is intended to mean the direction 90 degrees to the horizontal direction of the wall. The use of the term segment is intended to mean a portion of a block that is equal in dimensions and form as all other segments that are connected laterally in a block. The use of the term shell is intended to mean the wall thickness of an individual block. The use of the term wall is intended to mean a barrier or planar separation in addition to the traditional meaning of the term. The term wall thickness is intended to mean the thickness of an entire block segment. The use of the term CMU is intended to mean the concrete masonry unit used in traditional concrete wall construction. The composition percentages referenced in this patent are all weight percent (%). Wood fiber is understood to be from trees such as pine, fir, bamboo etc. and not annual growth plants. The wood fiber referenced in this patent can be that recovered from pulp mill wastewater and contain adhered contaminants such as Calcium Carbonate. An clearance fit is intended to mean when there is a gap between pieces or parts pace making an assembly without having to deform either part like that in an interference type of fit such as a snap or press fit.

(14) The present invention is intended to provide a methodology for reducing the labor cost associated with building walls similar to what would be constructed using concrete masonry units (CMU's). The design is for a multi-segment construction block that interlocks horizontally, vertically, and orthogonally, does not require mortar and is self-aligning.

(15) The dimensions of the block as per its preferred embodiments are proposed to be similar to those of commercially available CMU's (FIG. 1) which are typically used to construct walls approximately 150 mm, 200 mm or 300 mm thick. The dimensions are not restricted to those listed here and can be anything that is manufacturable. Figure I shows the orientation of a typical CMU with the end of a block (101) and the exposed face (102) of a block.

(16) The block in the present invention is segmented with the width or thickness (201) of each segment equal to the length of each block segment (202). The length of the block (203) is an even multiple of the segment length. FIG. 2 shows a block with 3 segments. The exposed height of the block and segment (204) is normally the same as the segment length and width but can be any height.

(17) Each segment has a male lip (205), (301) and a female inset (401) that span the perimeter of each segment and interlock vertically in a clearance fit with the male lips fitting into the female insets of each block. While the lip and inset are shown in FIG. 4 to span the entire perimeter of each segment it is not necessary and depends of the structural requirements of the particular application.

(18) Each segment can have holes oriented horizontally (206) in the lip and inset areas so that when the blocks are interlocked the holes align horizontally. The holes are intended to accommodate rebar, bolts, rivets or pins to provide additional vertical and horizontal reinforcement as necessary. Each hole adjoining two blocks can have a bolt, rivet or other fastening device to firmly join only the two adjoining blocks. The holes can also be used as passages for wire, conduit and pipe to supply utilities along a wall. Additionally the blocks can have vertical passages (207) that can be used for mechanical reinforcement as necessary or as passages for utilities. Each segment is hollow and aligns with the segment below it allowing for clear passage from the top of the wall to the bottom. This passage can be filled with concrete or rebar or other reinforcing material as needed for the structural requirements of the application or can be filled with loose insulating material such as foam, rice hulls, cellulose, soil, rocks, etc. Block shell thicknesses (301) can be varied with the mold depending upon the mechanical requirements of the application and are typically less than 25 mm.

(19) The blocks do not require mortar or sealant or adhesive for structural integrity but they can be used between blocks during installation for additional structural reinforcement or weatherability as necessary. FIG. 3 shows the top of an individual segment with channels for (302), (303) for sealant, adhesive, an O-ring or gasket. FIG. 4 shows a corresponding female inset (401) on an individual segment.

(20) FIG. 5 shows the interlocking detail of assembled blocks with the male lip (501) and female inset (502) as well as the location of a horizontally located hole (503) for reinforcement or for a passage.

(21) FIG. 6 shows two interlocking blocks with offset segments. While the blocks can be installed without offsetting the segments, an offset will provide additional structural integrity (especially in shear) as well as provide automatic alignment for the wall section.

(22) FIG. 7 shows two interlocking blocks oriented orthogonally to make a corner.

(23) Because the blocks have multiple segments, individual segments may be necessary to complete a wall section and make the blocks line up vertically even at the end. Individual blocks may be manufactured for this purpose or multi-segment blocks can be cut between segments to make single segment blocks. FIG. 7 shows a wall section utilizing a single segment block (801)

(24) FIG. 9 shows a version of the block with an end face that has a vertical protrusion (901) that can be used to complete walls where a window or door opening is desired. The protrusion can be used to aid in the installation of windows or doors by providing a fastening guide. Additionally, special blocks can be made that have protrusions similar to (901) but located on the exposed top or bottom of a block where a window or door will be installed. Special blocks with sealed top or bottom surfaces may also be fabricated for starting the bottom of a wall or terminating the top of a wall but with a corresponding interlocking lip or inset to allow connecting with the corresponding blocks above or below.

(25) Blocks can also have ports for water fixtures or wiring outlets as desired which can be configured from the inside of a block due to the accessibility provided by the hollow nature of each segment.

(26) FIG. 10 shows the exposed face of a block with optional chamfers (1001) that may be desired to aid in sealing the wall from water intrusion.

(27) To compete with CMU's the blocks need to be made from a low-cost material with strength equal or greater than that of concrete and have a low coefficient of thermal expansion. The blocks may be made by compression molding, blow molding, rota-molding or injection molding with some post-molding operation such as hole drilling or eliminating exterior molding draft necessary.

(28) Although any moldable material can be used for this invention, probably the best mechanical properties per unit cost would be a natural fiber reinforced thermoplastic composite. The ideal material would be molded from a composite of natural or synthetic fibers Gute, wood, flax, kenaf, cotton, hemp, bamboo, cellulose, ramie, banana, etc.) and thermoplastics (polyolefins, nylon, PVC, polyesters, PLA, etc.) The ideal natural fiber thermoplastic composite material would have a compression strength greater than 60 MPa and a coefficient of linear thermal expansion (CLTE) less than 0.0002/ C. With a compression strength of >4 times that of the typical concrete block material (about 14 MPa), these natural fiber thermoplastic composite materials will allow the design of a block based on compression strength with the shell thickness of a typical concrete block if creep is not an issue.

(29) The natural fiber composite formulation can include additives such as pigments (iron and other metal oxides, zinc ferrite, carbon black, titanium dioxide, etc.), UV light stabilizers (HALS, titanium dioxide, carbon black, nickel quenchers, benzophenones, benzotriazoles), antioxidants (hindered phenols, phosphites, thioesters, heat stabilizers; (organophosphites, hindered phenols), fungicides (zinc borate, microban.), coupling agents (maleated polyolefins, maleic acid grafted styrene-ethylene-butadiene, silanes) and fire retardants (magnesium hydroxide, alumina trihydrate, borates). If the exposed part of the board is coated or not exposed to light or fire, the UV stabilizers, pigments and fire retardants are not necessary.

(30) Alternatively, depending upon the demands of the application, the blocks can be made from recycled plastics including polyolefins, nylon, PVC, polyesters and mixtures thereof With mixtures of different types of plastic a suitable coupling agent or compatibilizer such as a silane or maleic acid grafted polymer or suitable block copolymers containing segments that are compatible with the different polymers in the mix. Styrene ethylene butylene styrene triblock copolymer (SEBS) is one compatabilizer that can improve properties of polymer blends. Natural, synthetic or mined particles such as talc, calcium carbonate, clay, mica, carbon and nanoparticles of these minerals, rice hulls, flax shive, wood sawdust, bagasse, core from hemp or kenaf, etc. may also be used instead of fibers. Recycled natural and synthetic fibers recovered from mattresses, furniture or carpets will also work.

(31) A more typical natural fiber thermoplastic composite with recycled plastic and fillers rather than fibers might have coefficient of linear thermal expansion less than 0.0003/ C. and compression strength greater than 40 MPa which would be suitable for many block applications.

(32) In some instances, synthetic fibers such as glass, Kevlar and basalt may be cost effective as well as using a thermoset resin with catalyst such as an epoxy or polyester resin.

(33) If creep is an issue, it may be desirable to cross-link the thermoplastic to prevent movement, especially under sustained loads and high temperatures. High density polyethylene is particularly suitable for cross-linking and can be performed in the mold if the temperature of the composite in the mold is high enough for the cross-linking to initiate. There are many cross-linking agents but for high density polyethylene (HDPE), tert butyl cumyl peroxide (BCUP) is commonly used at a composition of 2% of the weight of the polyethlene. Polypropylene and other thermoplastics have their particular cross-linking agents that may also be suitable for molding thermoplastic natural fiber composite blocks.

(34) While specific embodiments have been shown and described, many variations are possible. With time, additional features may be employed. The particular shape or configuration of the platform or the interior configuration may be changed to suit the system or equipment with which it is used.

(35) Having described the invention in detail, those skilled in the art will appreciate that modifications may be made to the invention without departing from its spirit. Therefore, it is not intended that the scope of the invention be limited to the specific embodiment illustrated and described. Rather, it is intended that the scope of this invention be determined by the appended claims and their equivalents.

(36) The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.