Apparatus For Providing An Interlocking Thermoplastic Building Blocks

Abstract

Embodiments of the present disclosure provide an apparatus for providing an improved building block. The disclosure provides for a block made from recycled or new thermoplastic materials or other blend of materials. The new block design provides for geometric interlocking capabilities from block to block, layer to layer and wall to wall via an Interlocking Post and screws. This Post will not only mechanically interlock the block system but will as well mechanically hold the block in position via a metal screw.

At least the following is claimed: 
     
         1 ) A new apparatus of a construction block  FIG. 1 , that is designed to utilize recycled plastic material in part or in whole. The geometry of the structural block may be in the form of a rectangular box as depicted in  FIG. 1 , of or in other shapes such as square cubes, parallelogram cubes or other shapes as required. The apparatus is designed to repurpose what would normally be waste stream plastic material (and other) for use as a natural insulator for an injection molded structural block. The aforementioned other materials could possibly be chemical additives (to make it more fire retardant), fiber additives, such as glass fibers or carbon fibers to make the block stronger and less resistant to polymer creep. Once the recycled material is repurposed into this closed loop system, blocks can be continuously reground into new material and remolded into blocks. It should be mentioned here, as well, that the described embodiments in no way are intended to limit the use of materials, plastic or other, in fact the reverse is true. New design applications will require the use of different geometry, possibly different base materials, both new and used, such as other plastics, steel, wood, man-made fibers, etc. 
     
     
         2 ) The apparatus of  claim 1 , further provides openings  102 , to be molded into the structural block that will allow the block to be much lighter in weight, while maintaining adequate structural integrity. These molded openings  102 , as well provide for an open column when blocks are stagger-stacked, thus providing a vertical column opening for concrete or other reinforcement to be poured or additional insulation to be added. 
     
     
         3 ) The apparatus of  claim 1 , further provides for these vertical openings,  102  to serve as new options as paths for electrical wiring, heating and air conditioning systems to be routed, constructed and assembled. As these openings,  102  are molded into each block, the open paths naturally provided by molding eliminate the need for technicians to cutaway what would be existing structural wall fabrication in either wood form or concrete form to create a path for wiring, HVAC or other. This new method creates an obvious major times savings, and therefore dollar savings for these services to be installed. This new method insulates and protects the service components within the wall by enclosing them within the boundaries of the block and said openings,  102  molded into the block. 
     
     
         4 ) The apparatus of  claim 1 , further provides for a spline and cavity self alignment system,  101  molded into the structural blocks. A spline and corresponding bottom cavity,  FIG. 2, 103  apparatus not only aligns the blocks in construction process but provides a unique positioning and anchoring mechanism for the screw. Furthermore, this spline,  101  design arrangement provides a critical surface to mechanically anchor the block together with the Interlocking Post,  FIG. 5  and typical industry metal screws designed for use in plastic materials. This top spline and bottom cavity,  101  and  103  geometry in the block design serve as functional wind and moisture barrier on both the top and bottom surfaces of the blocks. These surfaces,  101  and  103  are molded directly into the structural blocks for strength, ease of assembly and accurate placement of the blocks. 
     
     
         5 ) The apparatus of  claim 1 , further provides for a molded in “T” shaped cavity  100 , interlocking apparatus to mechanically hold structural blocks together as well as interlock one wall to a connecting perpendicular wall at the wall corners. This “T” shaped cavity,  100  molded into each end (lengthwise) of the block provides for connection of these structural blocks devoid of any special industry skills as is now required for cinder block and mortar construction. Time and labor savings are a direct result of this alignment and attachment system, along with other obvious construction saving techniques that are not available today in cinder block construction. This system is uniquely stronger than conventional cinder block wall construction, is easier to construct and mechanically attaches block together rather than relying heavily on a rather weak chemical attachment and mechanical attachment. 
     
     
         6 ) The apparatus of  claim 6 , further provides for an “Interlocking Post”,  FIG. 5  that interlocks and holds block to block and wall to wall via the geometry of the molded in cavities,  100  incorporated into individual blocks at each end and the corresponding shape molded into the Interlocking Post. The Interlocking Post,  FIG. 5  also fills the vertical cavity left when two blocks are positioned “end to end” for construction, thereby eliminating voids and cracks that would normally allow air and moisture to penetrate through the wall at the joining location. 
     
     
         7 ) The apparatus of  claim 6 , further provides for a vertical thru hole and counter-bored shape into the Interlocking Post,  502  “molded in” to access the attachment of a metal screw or other and to attach and anchor the Interlocking Post to the molded in cavity shape of the blocks. This creates a sturdy mechanical attachment at each end of the blocks lengthwise but as well anchors a block layer to the layer below it. 
     
     
         8 ) The apparatus for  claim 6 , further provides for the designed continuation of the Interlocking Post spline shape to match the geometry of the splines and cavities,  102  molded into the blocks, This design geometry is intended as well to minimize wind and moisture penetration through the wall. As a final precaution, adhesive caulking can be installed into the block joint assembly, either prior to or after stacking of the blocks. Here again, it should be emphasized that the above described embodiments of the present disclosure, particularly the illustrated embodiments, are merely examples of possible implementations to help determine a better understanding of the principles of the disclosure. 
     
     
         9 ) The apparatus of  claim 6  further provides for wing shaped out-board structures,  FIG. 5, 500  molded into the main body of the Interlocking Post,  FIG. 5 . These wing shapes, for lack of a better term, allow the post to attach and hold two blocks  100 , together in the X and Y positions and in alignment. 
     
     
         10 ) The apparatus of  claim 6 , further provides surfaces and geometry to hold two blocks together in the Z position by utilizing the bottom surface of the wing structure of the Interlocking Post. A permanent holding of the Interlocking Post,  FIG. 5  in the X,Y,Z position is accomplished by the mechanical attaching screw. 
     
     
         11 ) The apparatus of  claim 6 , further provides for a thru hole,  502  in the Interlocking Post,  FIG. 5 , that is vertically positioned in the center of the block. This thru hole,  502  is counter-bored near the top of the Interlocking Post,  FIG. 5  and is located centrally within the post to allow the mechanical screw,  FIG. 6  to apply equal force from the bottom of the winged structure,  501  and as well centrally position and hold the blocks via the molded in cavities,  100  via a force from the screw,  FIG. 6 . 
     
     
         12 ) The apparatus of  claim 12 , further provides for a designed metal screw,  FIG. 6  to mechanically attach (via threads in the screw) and hold in position the Interlocking Post,  FIG. 5 , and thereby hold and position the blocks via their injection molded cavities,  100 . 
     
     
         13 ) The apparatus of  claim 6  further provides for a designed and injection molded barrier structure  FIG. 5 , in the top of the block designed to restrict any wind, moisture or other contaminants from penetrating the wall structure. This barrier,  503  is designed to be of a common height as adjacent block splines,  101  thereby continuing the interlocking and aligning spline,  101  geometry through the block system.