CA2297380A1

CA2297380A1 - Modular construction blocks

Info

Publication number: CA2297380A1
Application number: CA 2297380
Authority: CA
Inventors: Bruce Karlstrom
Original assignee: SPIRITWOOD Ltd
Current assignee: SPIRITWOOD Ltd
Priority date: 2000-01-21
Filing date: 2000-01-21
Publication date: 2001-07-21

Abstract

The invention comprises a plurality of modular block elements, a kit and an assembly of such elements, and a method for such assembly. Each of the blocks has an inset cut at one or both ends and may have a central channel, the dimensions of such cut(s) and channel chosen so as to allow formation of one or more lap joints between two or more blocks. The ends, cuts and channels of the blocks are cut at angles of 60, 90 or 120 degrees to a reference side of the block to allow for construction of open or closed geometric structures with co-planar and perpendicular branches. Such structures may include walls, garden planters, and fences.

Description

TITLE OF THE INVENTION
MODULAR CONSTRUCTION BLOCKS
o TECHNICAL FIELD OF THE INVENTION
This invention relates to modular elements for constructing walls, planters, fences or other vertical structures. More particularly, the invention relates to modular building blocks provided with surfaces adapted to interlock s one block with another.
The invention has application in the fields of construction and landscaping, as well as in the toy industry.

BACKGROUND OF THE INVENTION
It is known in the prior art to provide a building system comprising modular interlocking blocks adapted to overlap at a variety of angles.
is Examples of such blocks are disclosed in U.S. Patent No. 4,736,550 to Hawranick, and U.S. Design Patent No. 326,531 to Lewis. Hawranick discloses blocks having generally triangular sides in which the overlapping projections extend at various angles to the longitudinal horizontal plane.
Lewis teaches a building block with lateral projections cut to a variety of 2o angles in relation to the transverse horizontal plane, and adapted to overlap with complementary projections on other blocks.
It is also known to provide T-shaped overlapping block elements. Such blocks are disclosed in United States Patent 4,123,881 to Muse, and U.S.
2s Patent No. 4,794,749 to Marcel. The blocks described in Muse comprise horizontal T-shaped blocks designed to be assembled such that the stem of the T is in the same horizontal plane as the top of the T.
Marcel teaches T-shaped and Z-shaped blocks in which the overlapping 3o projections comprise angles in relation to the transverse vertical plane.
The o blocks in Marcel are adapted to be assembled upright or laid flat in the construction of wall-like structures.
There are a number of desirable objectives in relation to modular block elements. The blocks should be relatively lightweight for ease of s transportation, handling and assembly. The blocks should preferably be adapted to form a variety of vertical structures having a combination of linear, acute angled and obtuse angled sides. Ideally, angles of 60, 90 and 120 degrees in relation to the longitudinal vertical plane should be available to enable efficient construction of closed geometric structures. Ideally, the to blocks should also be adapted to permit branching of the walls of the structures in both horizontal and vertical planes.
Various prior art approaches achieve some of these objectives, but with varying success. For example, in the case of U.S. Patent No. 4,123,881 to is Muse, a corner formed from the T-shaped blocks can only be assembled with the T-blocks on their sides. The block dimensions do not permit blocks to form a clean lap joint at right angles if the blocks are in an upright position.
The blocks in Muse also do not permit 60 and 120 degree angles to be formed in the wall structures.
2s The prior art blocks disclosed in Hawranick and Lewis do not permit angling of walls, and do not permit branching of structures. The blocks described in Marcel do not appear to permit the construction of wall structures having angles other than 90 degrees.
It is an object of this invention to permit construction of a wider variety of open and closed geometric structures than are possible using the existing prior art.
3o It is another object of this invention to provide such elements which may be assembled into a structure with vertical branches, or both horizontal and vertical branches. Prior art approaches permit branching in one plane only.
3s It is a further object of this invention to provide blocks which are easy to manufacture, transport and store. Prior art assemblies often were composed 0 of irregularly shaped blocks not conducive to rapid, compact stacking, or not easily cut from wood.
It is yet another object of this invention to improve the durability and load bearing capacity of the block elements and of the resulting vertical structure.
It is still a further object of this invention to provide a method of assembly using commonly available bolt means and avoiding use of mortar or other binding substance, allowing greater ease of assembly and disassembly to than permitted using the prior art.
SUMMARY OF THE INVENTION
is The invention comprises a plurality of modular construction blocks, a kit and an assembly of such blocks, and a method for their assembly.
The blocks of the invention are adapted to interconnect in a lap joint formed between one end of a first block and an end or a central channel of a 2o second block to create overall a wall, planter, fence or other vertical structure.
One embodiment of the invention comprises blocks of small dimensions which are suitable as toy construction sets.
In one of its aspects, the invention comprises a block having parallel 25 sides defining a width therebetween and opposed parallel faces defining a thickness therebetween, wherein said block further comprises a first angle of 60 degrees defined between one side and a first end of said block, and a second angle of 120 degrees between said side and a second end of said block, a flat-bottomed cut at said first end, said cut having an inner edge parallel to said 3o end, the distance between the end and the inner edge being equal to the width of the block, and the depth of the cut being equal to one half the thickness of the block, a second flat-bottomed cut at said second end and on the same face as said first cut, said second cut having an inner edge parallel to said second end, the distance between the second end and the inner edge being equal to the 35 width of the block, and the depth of the cut being equal to one half the thickness of the block.

o In another of its aspects the invention comprises a block having parallel sides defining a width therebetween and opposed parallel faces defining a thickness therebetween, wherein said block further comprises a first angle defined between one side and a first end of said block, and a second angle defined between said side and a second end of said block, at least one of said s first and second angles being other than 90 degrees; a flat-bottomed cut at said first end, said cut having an inner edge parallel to said end, the distance between the end and the inner edge being equal to the width of the block, and the depth of the cut being equal to one half the thickness of the block, a second cut at said second end and on the same face as said first cut, said second cut to having an inner edge parallel to said second end, the distance between the second end and the inner edge being equal to the width of the block, and the depth of the cut being equal to one half the thickness of the block.
In yet another of its aspects, the invention comprises a block having a 1 s first such cut in one face at one end and a second such cut in one side at the opposite end.
In a further of its aspects, the invention comprises a block having a first such cut in one face at one end and a second such cut in the opposite face at 2o the opposite end.
In still another of its aspects, the invention comprises a block having a transverse channel on the same side or face as one cut of the block, said channel half as thick and of the same width as the block, having parallel 2s vertical sides, and set at an angle of 60, 90 or 120 degrees relative to one side of the block.
Other aspects of the invention will be appreciated by reference to the description of the preferred embodiments which follows and to the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by reference to the preferred embodiment and the drawings thereof in which:

o Figure 1 is a perspective top view of the preferred embodiment of a block showing 60 degree and 120 degree co-lateral cuts;
Figure 2 is perspective top view of the preferred embodiment of the assembly according to the invention depicting a plurality of the preferred s embodiment of the block assembled into an hexagonal planter;
Figure 3 is a cross-sectional view of an embodiment of the assembly according to the invention through line 3--3 of Figure 2.
to Figure 4 is a perspective top view of a second embodiment of the assembly according to the invention depicting two blocks forming a 60 degree angle.
Figure 5 is a perspective top view of a third embodiment of a block is showing a 90 degree cut at one end and no cut at the opposite end.
Figure 6 is a perspective top view of a fourth embodiment of a block showing a 90 degree cut at one end and a 60 degree cut at the opposed end.
2o Figure 7 is a perspective top view of a fifth embodiment of a block showing a 60 degree cut in one face at one end and a 90 degree cut in a side at the opposite end of the block.
Figure 8 is a perspective top view of a sixth embodiment of a block 2s showing 90 degree cuts in the same face at opposite ends of a block and a degree transverse channel in the same face of the block.
Figure 9 is an exploded view of a third embodiment of the assembly according to the invention, depicting an assembly of three blocks;
Figure 10 is a partially exploded second view of the embodiment shown in Figure 9;
Figure 11 is perspective top view of a fourth embodiment of the 3s assembly according to the invention depicting a right-angled stepped retaining wall;
s o Figure 12 is a perspective top view of a fifth embodiment of the assembly according to the invention depicting a plurality of blocks assembled into a branching structure.
s DETAILED DESCRIPTION OF THE BEST MODE AND PREFERRED
EMBODIMENT OF THE INVENTION
As shown in Fig. 1, the preferred embodiment of the invention comprises a block having parallel sides 2, 4 defining a width 6, parallel faces l0 8, 10 defining a thickness 12, and opposed ends 14, 16. The angle between one side 2 and a first end 14 is 60 degrees as indicated by the numeral 18.
The angle between said side 2 and the opposite end 16 is 120 degrees, as indicated by the numeral 20.
is Each block further comprises at said first end 14 a first flat-bottomed cut 22 and at said opposite end 16 a second flat-bottomed cut 24, both cuts 22, 24 having an inner edge 26, 28 parallel to said ends, the distance 29 between each end 14, 16 and its corresponding inner edge 26, 28 being equal to the width 6 of the block and the vertical thickness 30 of each cut 22, 24 being one 2o half the thickness 12 of the block.
Fig. 2 shows one embodiment of an assembly of the blocks of the preferred embodiment, each block having one 60 degree end 14 and one 120 degree end 16. In the assembly, the 60 degree end 14 of a first block 32 may 2s be overlaid with the 60 degree end 14 of an inverted second block 34 to form an internal angle between the inner sides of the joined blocks of 120 degrees, indicated by the numeral 36. The 120 degree end 16 of the inverted second block 34 may then be overlaid with the 120 degree end 16 of a third block 38 to create a second internal angle of 120 degrees, indicated by the numeral 40.
3o Similarly, the 60 degree end 14 of the third block 38 may be overlaid with the 60 degree end 14 of an inverted fourth block 42 to form a third 120 degree internal angle indicated by the numeral 44. Continuation of this process with six identical blocks will result in construction of the closed hexagonal structure shown in Fig. 2. Vertical height is achieved by layering rows of blocks on top 3s of one another.

o The specific angles of the ends of the blocks and the dimensions of the cuts allow the formation of lap joints between complementary ends of two blocks. As also shown in Fig. 2, the lap joint 46 formed by the overlaying of two blocks results in continuity between the sides and faces of adjacent blocks in the assembled structure. As the thickness 30 of each cut is one half the s thickness 12 of the block, the overlaying of the complementary ends of two blocks creates a uniform thickness equal to the thickness of the block. This allows the formation of a flush surface defined by the faces of adjacent blocks.
Similarly, as the width of the cut is equal to the width of the block, the lap joints formed result in a smooth line of connection between the inner sides and o a smooth line of connection between the outer sides of adjacent blocks.
As shown in Figs. 1 and 3, in the preferred embodiment of the elements according to the invention, a circular hole 48 extends through each end of the block centred equidistant from each side and from the end of the block. The ~5 holes 48 on the overlaid ends of two blocks will align, permitting the insertion therethrough of a bolt 50 to hold the blocks in place. Additional layers of blocks may also be added, with holes 48 aligned. A nut 52 may be fastened to the end of the bolt once the final layer of blocks has been added.
2o Referring now to Fig. 1, the edges of each block preferably are beveled between each side and each face 54, and between each end and each face 56.
Such beveling provides improved load-bearing capacity.
While the preferred embodiment of the assembly according to the 25 invention comprises lap joints displaying 120 degree internal angles, the blocks alternatively may be assembled to form lap joints displaying 60 degree angles. As shown in Fig. 4, this may be achieved by overlaying the 120 degree end 16 of a first block 58 with the 120 degree end 16 of an inverted second block 60 to form a resultant internal angle of 60 degrees, as indicated by the 3o numera161.
Other embodiments of the block of the invention are possible. It is known in the prior art to provide T-shaped blocks having opposed 90 degree ends which may be overlaid to form lap joints at 90 degrees or 180 degrees in 35 the horizontal plane. One embodiment of the present invention shown in Fig.
S comprehends a block having a 90 degree end 62 and cut 64 at one end and no o cut at the opposite end 66. Fig. 6 depicts a block having a 90 degree end and cut at one end 68 and a 60 degree end and cut at the opposite end 70.
Other embodiments of the invention include variations in the alignment of the cuts at opposed ends of a block. In the preferred embodiment shown in s Fig. 1, the cuts 22, 24 are on the same face 8 of the block. In the block shown in Fig. 7, one cut 72 is on a face 8 of the block, while the cut 74 on the opposite end of the block is on a side 2 of the block. The cuts may also be on opposite faces or opposite sides of a block (not shown).
o While the blocks described above permit joining of two blocks end to end, joining of a first block to three other blocks is desirable in order to permit more complex structures to be constructed. As shown in Fig. 8, in order to achieve this objective, one or more blocks may further comprise a transverse channel 76 with dimensions half as thick and of the same width as the block, ~s and having parallel sides perpendicular to the base of the channel. The angle between the sides of the channel and one side of the block may be 60 degrees, 90 degrees, or 120 degrees as indicated by the numeral 77. The channel may be co-lateral as shown in Fig. 8, in perpendicular relationship or on the opposite face relative to the cut at one end of the block. A circular hole 78 2o extends through the centre of the channel to the opposite face of the block.
The method of assembly according to the invention, as depicted in Figs.
9 and 10, comprises sequential joining of a plurality of blocks, such plurality not exclusively comprising blocks having co-lateral 90 degree cuts, in which a 2s first block 80 is placed alongside a second block 82 so as to overlap a cut 84 of the first block with a channel 86 of the second block, thereby forming an internal lap joint between the two blocks. A third block 88 is then added by overlaying one end 90 of the third block with an exposed end 92 of the second block 82.
Additional blocks may be added in a similar fashion to extend ends of the structure at 60, 90, 120 or 180 degrees in the same plane as the present orientation of the terminal block at each end of the structure. A particular end of the structure may be extended at 60 or 120 degrees by joining two 60 degree 3s ends or two 120 degree ends. A linear extension of 180 degrees may be formed by joining 60 degree and 120 degree ends, or by joining two 90 degree s o ends. A 90 degree extension may also be formed by joining two 90 degree ends.
Similarly, the structure may be extended at an angle of 60, 90 or 120 degrees out of the plane relative to the present orientation of the terminal block s at each end of the structure. This is achieved by first incorporating a block comprising either a perpendicular channel or a block having cuts in perpendicular relationship to one another, that is, having one cut on a face at one end and a second cut on a side at the opposite end of a block. The perpendicular channel or cut in a block may be at 60, 90 or 120 degrees o relative to one of the sides of the block. Choice of angle of the perpendicular channel or cut will allow extension of the structure at that angle through the incremental addition of blocks.
As shown in Fig. 3, a circular bolt is placed through the aligned holes ~s of the lap joint. The bolt should be of a length sufficient to extend from the base to the top of the vertical structure. Once the desired vertical height is achieved for a particular section of the structure, a nut is attached to the bolt to fix the blocks in position.
2o Various block elements may be used to construct a wide variety of quickly and easily assembled open or closed geometric structures which maintain relatively flat sides and faces. The angles, relative dimensions and relative orientations chosen for the cuts and channels of the blocks permit a very diverse range of possible structures using a limited variety of discrete 2s blocks.
Various embodiments of the assembly according to the invention can be used as walls, fences, planters, yard borders and other structures. For example, the hexagonal planter depicted in Fig. 2 is comprised of the block shown in 3o Fig. 1. An open geometric structure such as the retaining wall shown in Fig.
11 can be constructed using the single cut block 94 of Fig. 5 in combination with other blocks.
In another embodiment of the assembly according to the invention, a 3s branched structure as shown in Fig. 12 is constructed which incorporates blocks with channels 96 and blocks having cuts in perpendicular relationship to one another 98 In yet another embodiment of the invention, the blocks are of small dimensions for use as a toy building block set.
It will be appreciated by those skilled in the art that other variations of s the preferred embodiment may also be practised without departing from the scope of the invention.
to

Claims

1. A block having parallel sides defining a width therebetween and opposed parallel faces defining a thickness therebetween, wherein said block further comprises:
a. a first angle of 60 degrees defined between one side and a first end of said block, and a second angle of 120 degrees between said side and a second end of said block, b. a flat-bottomed cut at said first end, said cut having an inner edge parallel to said end, the distance between the end and the inner edge being equal to the width of the block, and the depth of the cut being equal to one half the thickness of the block, c. a second flat-bottomed cut at said second end and on the same face as said first cut, said second cut having an inner edge parallel to said second end, the distance between the second end and the inner edge being equal to the width of the block, and the depth of the cut being equal to one half the thickness of the block.

2. A block having parallel sides defining a width therebetween and opposed parallel faces defining a thickness therebetween, wherein said block further comprises:
a. a first angle defined between one side and a first end of said block, and a second angle defined between said side and a second end of said block, at least one of said first and second angles being other than 90 degrees;
b. a flat-bottomed cut at said first end, said cut having an inner edge parallel to said end, the distance between the end and the inner edge being equal to the width of the block, and the depth of the cut being equal to one half the thickness of the block.

3. The block of claim 2 further comprising a second cut at said second end and on the same face as said first cut, said second cut having an inner edge parallel to said second end, the distance between the second end and the inner edge being equal to the width of the block, and the depth of the cut being equal to one half the thickness of the block.

4. The block of claim 3 wherein the first cut is on a face of the block and the second cut is on a side of the block.

5. The block of claim 3 wherein the first and second cuts are on opposite faces of the block.

6. The block of any of claims 1 to 5 wherein said block further comprises a circular hole through each end equidistant from each side and the proximate end.

7. The block of any of claims 1 to 5 further comprising a transverse channel on the same side or face as one cut of the block, said channel half as thick and of the same width as the block, having parallel vertical sides, and set at an angle of 60, 90 or 120 degrees relative to one side of the block.

8. The block of claim 7 wherein the channel is in perpendicular relationship to one cut of the block.

9. The block of claim 8 wherein the channel is on the opposite face to one cut of the block.

10. The block of any of claims 7 to 9 wherein said block further comprises a circular hole extending through each end positioned equidistant from each side and the proximate end, and a circular hole extending through the centre of said channel.

11. The block of any of claims 1 to 10 wherein said block further comprises beveling between each side and each face and between each end and each face.

12. A block having parallel sides defining a width therebetween and opposed parallel faces defining a thickness therebetween, wherein said block further comprises:
a. a first angle of 60 or 120 degrees between one side and a first end, and a second angle of 60 or 120 degrees between said side and a second opposing end of said block;

b. a flat-bottomed cut at said first end, said cut having an inner edge parallel to said end, the distance between the end and the inner edge being equal to the width of the block, and the depth of the cut one half the thickness of the block;
c. a second flat-bottomed cut at said second end, said cut having an inner edge parallel to said second end, the distance between the second end and the inner edge being equal to the width of the block, and the depth of the cut one half the thickness of the block.

13. The block of claim 12 further comprising a circular hole through each end equidistant from each side and the proximate end.

14. The block of claim 12 wherein the first and second cuts are on the same face.

15. The block of claim 12 wherein the first cut is on a face of the block and the second cut is on a side of the block.

16. The block of claim 12 wherein the first and second cuts are on opposite faces of the block.

17. The block of any of claims 12 to 16 wherein said block further comprises a transverse channel, said channel half as thick and of the same width as the block, having parallel vertical sides, and set at an angle of 60, 90 or 120 degrees relative to one side of the block.

18. The block of claim 17 wherein the channel is co-lateral to the first cut.

19. The block of claim 17 wherein the channel is in perpendicular relationship to the first cut of the block.

20. The block of claim 17 wherein the channel is on the opposite face to the first cut of the block.

21. The block of any of claims 17 to 20 wherein said block further comprises a circular hole extending through each end positioned equidistant from each side and the proximate end, and a circular hole extending through the centre of said channel.

22. A kit of block elements, each block comprising parallel sides defining a width therebetween and opposed parallel faces defining a thickness therebetween, wherein said block further comprises:
a. a first angle defined between one side and a first end of said block, and a second angle defined between said side and a second end of said block, at least one of said first and second angles being other than 90 degrees;
b. a flat-bottomed cut at said first end, said cut having an inner edge parallel to said end, the distance between the end and the inner edge being equal to the width of the block, and the depth of the cut being equal to one half the thickness of the block.

23. The kit of claim 22 wherein the block further comprises a transverse channel on the same side or face as one cut of the block, said channel half as thick and of the same width as the block, having parallel vertical sides, and set at an angle of 60, 90 or 120 degrees relative to one side of the block.

24. An assembly of blocks elements, each block comprising parallel sides defining a width therebetween and opposed parallel faces defining a thickness therebetween, wherein said block further comprises:
a. a first angle defined between one side and a first end of said block, and a second angle defined between said side and a second end of said block, at least one of said first and second angles being other than 90 degrees;
b. a flat-bottomed cut at said first end, said cut having an inner edge parallel to said end, the distance between the end and the inner edge being equal to the width of the block, and the depth of the cut being equal to one half the thickness of the block.

25. The assembly of claim 24 wherein each block further comprises a transverse channel on the same side or face as one cut of the block, said channel half as thick and of the same width as the block, having parallel vertical sides, and set at an angle of 60, 90 or 120 degrees relative to one side of the block.

26. A method of assembly of blocks comprising a. overlaying a first end of a first block, said first block comprising a first angle of 60 degrees defined between one side and a first end of said block, and a second angle of 120 degrees between said side and a second end of said block, a flat-bottomed cut at said first end, said cut having an inner edge parallel to said end, the distance between the end and the inner edge being equal to the width of the block, and the depth of the cut being equal to one half the thickness of the block, and a second flat-bottomed cut at said second end and on the same face as said first cut, said second cut having an inner edge parallel to said second end, the distance between the second end and the inner edge being equal to the width of the block, and the depth of the cut being equal to one half the thickness of the block, with an identical first end of an inverted second identical block to form an internal angle between the inner sides of the joined blocks of 120 degrees, subsequently overlaying the second end of the second block with a complementary first end of an identical third block, and continuing to overlay identical blocks end to complementary end until six blocks have been joined in a closed geometric structure, b. adding additional layers of blocks on top of underlying layers, and c. inserting a bolt of sufficient length through each set of aligned complementary ends and fastening a nut to the end of each bolt.