OA21176A - Interlocking building blocks and mortarless interlocking building system. - Google Patents

Abstract

A mortarless interlocking building block for constructing walls and/or partitions of a building including a solid moulded plastic body having a front face, a rear face, opposed top and bottom faces and opposed end faces, the opposed front and rear faces being substantially identical and including at least two vertically extending dovetail protrusions defining a dovetail recess for matingly receiving a dovetail protrusion of another building component, one of the opposed end faces having at least one vertically extending recess and the other of the end faces having at least one vertically extending protrusion for mating with a recess of another building block to interconnect adjacent blocks in end-to-end relation, and the top face having at least two tubular protrusions and the bottom face having at least two tubular recesses to lock stacked building blocks.

Description

INTERLOCKING BUILDING BLOCKS AND MORTARLESS INTERLOCKING BUILDING SYSTEM

FIELD

The présent invention relates to building blocks for a mortarless interlocking building System and methods for making same.

BACKGROUND

Compressed earth bricks and fired bricks hâve been used to construct buildings for thousands of years. One reason is that earth (clay, soil, rock) is a very good insulator/thermal mass against heat and cold. The big drawback for compressed earth bricks, concrète blocks, or even a fired brick is that they absorb water; the water expands when frozen, and over time the bricks crack and fall apart.

The single use nature of traditional building materials créâtes much unnecessary waste. The volume of construction waste generated worldwide every year will be 2.2. billion tons by the year 2025, of which only 48% is recycled. On average, every year more than 242,000,000 tons of plastic waste is produced. Of that amount, only about 9% is recycled.

A building System which addresses such shortcomings in the art would be désirable.

SUMMARY

In one aspect, the présent disclosure address three major issues at once: (i) the building components are made of currently unused and or under-utilized waste plastics and other waste aggregates to create a reusable, fully interlocking building system that drastically reduces the amount of waste created in the building process; (ii). the building components are comparable to and exceed concrète blocks in many metrics including strength, crack résistance, and water absorption; and (iii) the building System is highly versatile and will be able to be used for a wide range of permanent and temporary wall structures such as retaining walls, flood barriers, and foundations. The invention stands out from ail other Systems due to the fact that it interlocks on ail sides allowing for unmatched structural strength and versatility.

In one aspect, the présent disclosure relates to an interlocking construction system, also referred to as a building system, including interlocking components made of recycled materials. In one aspect, the interlocking components consist of 90% or greater of recycling materials. In another aspect, the interlocking components are made from a recycled thermal plastic and aggregate composite. In another aspect, the interlocking components include six-sided interlocking bricks, which six sides include interlocking components permitting the interlocking of the brick on ail six sides with other interlocking components. In another aspect, adhesives can optionally be used to adhéré the bricks to other interlocking bricks or components. Interlocking components may be finished with a click panel exterior. Interlocking bricks according to embodiments of the présent invention are stronger than concrète blocks and provide excellent résistance to water, insects, mould/mildew, storms, and high wind. Bricks according to embodiments of the présent invention are environmentally friendly, less expensive to build with than wood or concrète, and require little maintenance. Bricks according to embodiments of the présent invention can be used for a wide range of applications from retaining walls and flood barriers, to full building Systems and more. Building Systems according to embodiments of the présent invention may also be adapted for autonomous construction.

BRIEF DESCRIPTIONS OF DRAWINGS

For the purpose of illustrating the invention, the drawings show aspects of one or more embodiments of the invention. However, it should be understood that the présent invention is not limited to the précisé arrangements and instrumentalities shown in the drawings, wherein:

FIG. 1 is a perspective view of three building blocks according to embodiments of the présent invention;

FIG. 2 is a top view of a building block according to another embodiment of the présent invention;

FIG. 3 is a top perspective view of the block of FIG. 2;

FIG. 4 is a bottom perspective view of the block of FIG. 2;

FIG. 5 is a front perspective view of a side click panel according to an embodiment of the présent invention;

FIG. 6 is a rear perspective view of the side click panel of FIG. 5;

FIG. 7 is a top perspective view of a top cap according to an embodiment of the présent invention;

FIG. 8 is a bottom perspective view of the top cap of FIG. 7;

FIG. 9 is a perspective view of three building blocks according to embodiments of the présent invention;

FIG. ΙΟ is a top perspective view of the building blocks of FIG. 9 connected end to end and partially clad with side click panels according to embodiments of the présent invention;

FIG. 11 is a front perspective view of the building blocks of FIG. 10;

FIG. 12 is a side perspective view of a building block according to another embodiment of the présent invention;

FIG. 13 is an end perspective view of the building block of FIG. 12;

FIG. 14 is a side perspective view of the building block of FIG. 12 from the opposite end to that shown in FIG. 12;

FIG. 15 is an end perspective view of the block of FIG. 12 from the opposite end to that shown in FIG. 13;

FIG. 16 is a view of an interlocking building System kit according to an embodiment of the présent invention;

FIG. 17 is a top perspective view of walls of a partially completed structure made with a building block System according to embodiments of the présent invention;

FIG. 18 is a flow diagram of a method of manufacturing components of the présent invention;

FIG. 19 is a top down perspective view of a building block according to another embodiment of the présent invention;

FIG. 20 is a top down perspective view of a building block according to another embodiment of the présent invention;

FIG. 21 is a top perspective view of a gasket for use with the block of FIG. 20;

FIG. 22 is a perspective view of a partially completed wall assembled with blocks of FIG. 20; and

FIG. 23 is a is a top down perspective view of a building block according to another embodiment of the présent invention.

DETAILED DESCRIPTION

With reference to FIG. 1, in one embodiment, the présent invention relates to.a six sided interlocking construction block (and corresponding interlocking components) produccd from a heat extruded and form pressed mix of 90%+ recycled plastics and recycled aggregates. These blocks and corresponding components can be assembled for any range of applications; from retaining walls and flood barriers to full building wall construction. The blocks conform with typical North American framing standards (16c & 24c) and meet industry load/shear requirements. The blocks can be connected with interlocking exterior panels on one or both sides and can also be easily framed inside with a traditional stud structure. The blocks can be eut, screwed and drilled with less effort than traditional concrète blocks and without the nuisance of cracks and chips.

Referring initially to FIG. 2 to FIG. 4, in another embodiment, the présent invention relates to an interlocking building System which includes building blocks that interlock on ail six sides of the blocks. In one embodiment, the System includes a rectangular block 2 , eight inches in length and sixteen inches in height, but may be of other building dimensions. The block includes dovetail interlock protrusions 40 on side vertical faces 7, a dovetail protrusion 8 on an end face 110, a dovetail recess 6 on end face 14, tubular protrusions 160 on the top face 18 and tubular recesses 9 on the bottom face 20 of the block 2. The tubular protrusions 160 may also be considered male connectors and the tubular recesses 9 may also be considered to be female sockets. The dovetail interlock protrusions 40 define a dovetail a recess I there between. The edges 22 of the rims of the tubular protrusions 160 are rounded. The edges 10 of the tubular recesses 9 are chamfered. The centre of the dovetail protrusions 4 are spaced eight inches apart as illustrated by dimension line 5. Other spacings for the dovetail protrusions can be used. The corners 24 of the dovetail protrusions 40 are rounded. A first pair of tubular channels run from the tubular protrusions though the body of the block 2 to the tubular recesses 9. The first pair of tubular channels 3 may accommodate wiring, pipes, or extra reinforcement such as re-bar or poured concrète when the block is installed. A second pair of tubular channels 40, smaller in diameter than the first pair 3, run from the bottom face 20 through the body of the solid block 2 to the top face 18. The second pair of tubular channels 4 may accommodate can accommodate wiring or re-bar reinforcement (not shown). One or more latéral channels may be added to allow for the installation of recycled tire seals or more wiring options.

Referring to FIG. 5 and FIG. 6, the System may also include a side panel with a water lock design. The side panel includes an outside finished surface II, a inclined edge 12 on the top and bottom edges forming a v-lock to lock out water, a notch 13 and protrusion 16 for vertical interlock and also to lock out water, and dovetail protrusions 15 and dovetail recesses 30 on the rectangular inside face. As with the dovetail protrusions 40 of the block 2, the corners of the dovetail protrusions 15 are rounded to facilitate press fitting.

Referring to FIG. 7 and FIG. 8, the System can also include a top cap with a water lock design. The top cap panel includes a finished top surface 190 with a female cap interlock 170 and a tapered interlock 180 for water drainage. The bottom of the top cap includes, male cap interlock, circular recesses 210 with chamfered edges and a v-notch.

The finished surfaces of the side panel and the top cap can be finished with a wide range of finishes including, but not limited to, insulation, stone textures, solar voltaic intégration, or any other intégration with the corresponding interlocking System.

Referring to FIG. 9, the building blocks according to embodiments of the présent invention can be shorter or longer than the building blocks described with référencé to FIG. 2 to FIG. 4 and also illustrated as blocks 50, 60 and 2 in FIG. 9. For example, a shorter building block is illustrated as 60 in FIG. 9 and has only one dovetail protrusion on each side vertical face of the block, one tubular channel with a tubular protrusion and a tubular recess (not shown), and a one secondary channel smaller in diameter than the tubular channel. A longer building block is illustrated as 50 in FIG. 9 and has three dovetail protrusions on each side vertical face of the block, three tubular channel with a tubular protrusions and tubular recesses (not shown), and three secondary channels. The éléments of the block 50 and block 60 parallel those of block 2 which is described above with référencé to FIG. 2 to FIG. 4.

The building blocks 50, 60 and 2 may be joined end to end by the end dovetail protrusions in corresponding end dovetail recesses in adjacent building blocks as illustrated in FIG. 10 and FIG. 11. Side panels 52, 54, 56 and 58 of various lengths may be joined to the assembled blocks as illustrated in FIG. 10 and FIG. 11. The side panels include bevelled ends and tongue and grooves for connecting the panels one to the other and for forming a water résistant seal.

A building block according to another embodiment of the présent invention is illustrated in FIG. 12 to FIG. 15. The building block has the same éléments as the building block illustrated in FIG. 2 to FIG. 4 except that it also has a horizontal channel 55 which is open to the vertical tubular channels and is open on one vertical side.

A building Systems according to embodiments of the présent invention can include a kit of building blocks, side panels and top caps, such as the kit of building components illustrated in FIG. 16. The kit of FIG. 16 includes side panels of various lengths (shown in edge view) as indicated generally at 240, building blocks of various lengths (shown from the top) as indicated generally at 250 and top caps of various shapes and lengths (shown from the top) as indicated generally at 260. The top caps 260 include corner caps 261, cross caps 262, rectangular caps 263, square caps 264, three-pointed caps 265

Building Systems according to embodiments of the présent invention do not require cutting, and adhesives are optional, depending on the application. Systems of the présent invention can be assembled to form walls of a house or building as for example generally illustrated in FIG. 17. When placing the building blocks of the présent invention to form a wall, the first course is suitably placed on a foundation, aligned in a straight line and interlocked end to end by placing the end dovetail protrusions in corresponding end dovetail recesses in adjacent building blocks. Thereafter, a second course of building blocks is mounted on the first course and may be staggered relative to the first course, or may not be staggered relative to the lower course as illustrated in FIG. 17. When mounted on the first course, the tubular recesses in the building blocks in the upper course are registered with the tubular protrusions of the building blocks on the lower course. Walls formed with the building blocks can be finished with side click panels and top caps according to embodiments of the présent invention.

Referring to FIG. 19, in another embodiment, the présent invention relates to a rectangular block 2, eight inches in length and sixteen inches in height, but may be of other building dimensions. The block includes dovetail interlock protrusions 40 on side vertical faces 7, a dovetail protrusion 8 on an end face 110, a dovetail recess 6 on end face 14, tubular protrusions 160 on the top face 18 and tubular recesses (not shown) on the bottom face 20 of the block 2 which hâve the same structure as the tubular recesses 9. The tubular protrusions 160 may also be considered male connectors and the tubular recesses may also be considered to be female sockets. The dovetail interlock protrusions 40 define a dovetail a recess 1 there between. The edges 22 of the rims of the tubular protrusions 160 are rounded. The edges 10 of the tubular recesses are chamfered. The centre of the dovetail protrusions 4 are spaced eight inches apart as illustrated by dimension line 5. Other spacings for the dovetail protrusions can be used. The comers 24 of the dovetail protrusions 40 are rounded. A first pair of tubular channels can optionally run from the tubular protrusions though the body of the block 2 to the tubular recesses. A first pair of tubular channels may accommodate wiring, pipes, or extra reinforcement such as re-bar or poured concrète when the block is installed. A second pair of tubular channel, smaller in diameter than the first pair, can optionally run from the bottom face through the body of the solid block 2 to the top face 18. The second pair of tubular channels 4 may accommodate can accommodate wiring or re-bar reinforcement (shown as 308 in FIG. 22). One or more latéral channels may be added to allow for the installation of recycled tire seals or more wiring options. Additional channels 25 are provided, which can be partially in the dovetail protrusions 40 and can be in the main body of the block 2 itself, to reduce the weight of the block 2 and for thermal control during production. The channels 25 can be used for multiple purposes such as to accommodate wiring.

Referring to FIG. 20, in another embodiment, the présent invention relates to a rectangular block indicated generally at 70 which has the same éléments as the block 2 of FIG. 19, with the addition of grooves 302 for receiving of the gasket indicated generally at 80 shown in FIG. 21. The gasket 80 is formed of strips 303 joined in a grid pattern. The strips 303 are made of recycled tire seals but can be made of another material such as Silicon suitable for as a gasket sealing material. The gasket 80 can also be formed as a one piece grid. As seen in FIG. 22, the gasket 80 is shown installed in grooves 302 on block 70. The gasket 80 forms a watertight seal between stacked blocks 70.

FIG. 22 illustrâtes a partially completed wall of blocks 70 on a concrète slab footing 305 with threads rods 308 partially embedded and protruding from the footing 305.. The blocks 70 are shown with the rods 308 place up through in the channels 4. A block 70 is shown bolted down with bolts and washers 312 on the rods 308. Blocks 65 can be used in place of blocks 70.

Referring to FIG. 23, in another embodiment, the présent invention relates to a rectangular block indicated generally at 65. The block shares éléments in common with block 70 but is shorter, measuring sixteen inches in length, eight inches in width and four inches in height.

The présent invention in another embodiment relates to a method of manufacture of the building components using a composite material. Referring to FIG. 18, in one embodiment, the method of forming the composite mixture material includes step 100 comminuting recycled materials including a recycled polymer material and a recycled aggregate, step 200 mixing the comminuted materials, step 300 heating the mixed materials to a température to melt the polymeric material to form a fused together composite material, step 400 applying a compressive stress load to the composite mixture prior to solidification, step 500 moulding the mixture and step 600 cooling the mixture. In one embodiment, the comminuted recycled materials are fed through a large format (2 diameter or greater) heated auger or heated screw which mixes, compresses and heats the mixture across a heat spectrum from about 200°C to about 280°C. In one embodiment, the spacing between the auger blades decreases down the line such that the composite mixture can be progressively compressed. The resulting hot mixture is then put into a mould using one of several conventional methods such as injection moulding, extrusion moulding, or press moulding, as each component of the présent System may require. The heated mixture is cooled naturally and/or artificially.

In another embodiment, mixtures according to embodiments of the présent invention are heated to a température in the range of about 190°C to about 450°C, in a further embodiment, mixtures are heated to a température in the range of about 190°C to about 280°C, and in a still further embodiment, mixtures are heated to a température in the range of about 300°C to about 450°C. In a still further embodiment, shredded nylon rope can be used in a mixture according to the présent invention to strengthen it. In a still further embodiment, a mixture including shredded nylon rope can be heated to a température in the range of about 190°C to about 280°C.

Systems of the présent invention can also be adapted to be easily incorporated into autonomous construction.

Building components according the embodiments of the présent invention can be made from a composite materia! including of a wide range of recycled thermal plastics, including but not limited to PE, PET, and PS which are ground to about % inch particles and then blended with other ground up waste aggregates, including but not limited to, recycled concrète, brick, and/or glass. UV inhibitors and tire inhibitors as well as stabilizing agents can be added as they are needed (up to 10%). In embodiments of the présent invention, the building blocks are solid other than for the conduits discussed above.

The présent invention in another embodiment relates to a method of manufacture of the building components using a composite material. In one embodiment, the method of forming the composite mixture material includes comminuting recycled materials including a recycled polymer material and a recycled aggregate, mixing the comminuted materials, heating the mixed materials to a température to melt the polymeric material to form a fused together composite material, and applying a compressive stress load to the composite mixture prior to solidification. In one embodiment, the comminuted recycled materials are fed through a large format (2 diameter or greater) heated auger or heated screw which mixes, compresses and heats the mixture across a heat spectrum from about 200°C to about 280°C. In one embodiment, the spacing between the auger blades decreases down the line such that the composite mixture can be progressively comprcssed. The resulting hot mixture is then put into a mould using one of several conventional methods such as injection moulding, extrusion moulding, or press moulding, as each component of the présent System may require. The heated mixture is cooled naturally and/or artificially.

Claims (13)

1. LA mortarless interlocking building block for constructing walls and/or partitions of a building comprising:

   a solid moulded plastic body having a front face, a rear face, opposed top and bottom faces and opposed end faces, the opposed front and rear faces being substantially identical and including at least two vertically extending dovetail protrusions defining a dovetail recess for matingly receiving a dovetail protrusion of another building component, one of the opposed end faces having at least one vertically extending recess and the other of the end faces having at least one vertically extending protrusion for mating with a recess of another building block to interconnect adjacent blocks in end-to-end relation, and the top face having at least two tubular protrusions and the bottom face having at least two tubular recesses to lock stacked building blocks.
2. 2. The block of claim 1, further including at least one channel for receiving wiring, piping or reinforcement.
3. 3. The block of claim 1 or claim 2, wherein the corners of the dovetails are rounded.
4. 4. The block of any one of daims 1 to 3, wherein the edges of the vertically extending protrusions are rounded.
5. 5. The block of any one of daims 1 to 4, wherein the edges of the tubular recesses are chamfered.
6. 6. The block of any one of daims 1 to 5, wherein the solid material in the block comprises a mixture of a plastic and an aggregate.
7. 7. The block of any one of daims 1 to 6, wherein the plastic is a recycled plastic and the aggregate is a recycled aggregate.
8. 8. The block of any one of daims 1 to 7, further comprising at least one channel in the top face for receiving a gasket.
9. 9. The blocks of any one of daims l to 7, further comprising a sériés of channels in the top face in a grid pattem for receiving a gasket, wherein the gasket is formed of strips in a grid pattern.
10. 10. The block of any one of daims 1 to 7, further comprising at least one channel passing through the block between the top face and the bottom face for receiving a bar.
11. 11. A building System comprising at least one block of any one of daims 1 to 9 and further comprising:

    at least one mortarless side panel including a finished outside surface and at least one dovetail protrusion on an opposing surface for joining the side panel to the at least one blocks, and a connecter on each end of the panel for joining the side panel to other side panels, and at least one top cap including a finished top surface.
12. 12. A method of manufacturing mortarless building blocks, comprising the steps of:

    comminuting recycled matériels, mixing comminuted materials, heating the comminuted mixture, compressing the comminuted mixture, moulding the comminuted mixture, and cooling the comminuted mixture.
13. 13. The method of daim 12, wherein the compressing step is carried out using an auger.