Interlocking composite construction block improvements

Abstract

Embodiments relate to an enhanced method for building walls by primarily reducing the time for assembly. The designs are for molded multi-segment plastic composite construction blocks that interlock horizontally, vertically and orthogonally with a clearance-fit, do not require mortar for structural integrity and are self-aligning. The blocks are molded out of natural-fiber reinforced recycled thermoplastic composites and are stronger and lighter than CMU's.

1 . A segmented plastic composite construction block with each segment length equal to segment width allowing for assembly of walls with blocks that can interlock horizontally, vertically and orthogonally with lips and insets that have a clearance-fit and are located around the perimeter of each segment; wherein each block has more than one adjoining equal dimension segment; wherein each segment has a male lip that fits into the female inset on the block segment above or below it; and wherein the lip thickness is equal to the inset dimension. 
     
     
         2 . The block in  claim 1  wherein each segment has holes in the male and female interlocking parts that align horizontally allowing the passage of conduit, wiring, pipe, bolts, fasteners, rebar or other reinforcements. 
     
     
         3 . The block in  claim 1  wherein the thermoplastic composite comprises about 25 to 50 weight % hemp fiber. 
     
     
         4 . The block in  claim 1  wherein there are indications for drilling holes through the lips and insets. 
     
     
         5 . The block in  claim 1  wherein a metal wire or synthetic fiber mesh is molded into the exterior surface of the block. 
     
     
         6 . The block in  claim 1  wherein the horizontal mating surfaces of each segment are inclined about 5 to 30 degrees. 
     
     
         7 . Block in  claim 1  wherein the thermoplastic composite comprises about 5 to 20 weight % glass cenospheres. 
     
     
         8 . The block in  claim 1  wherein the thermoplastic composite comprises about 5 to 15 weight % silica. 
     
     
         9 . The block in  claim 1  wherein the thermoplastic composite comprises about 0.5 to 5 weight % thermoplastic elastomer. 
     
     
         10 . The block in  claim 1  wherein the thermoplastic composite comprises up to about 4 weight % un-melted thermoplastic film components. 
     
     
         11 . A molded, hollow, segmented thermoplastic plastic composite construction block with each segment length equal to segment width allowing for assembly of walls with blocks that can interlock horizontally, vertically and orthogonally with a web on the top face that has male pins around the perimeter of each segment at a regular spacing; a matrix of pins offset at this same spacing towards the center of the web of each segment and corresponding cavities located around the perimeter of the bottom, female face have a clearance fit with the corresponding pins. 
     
     
         12 . The block in  claim 11  wherein the thermoplastic composite comprises about 25 to 50 weight percent hemp fiber. 
     
     
         13 . The block in  claim 11  wherein a metal wire or synthetic fiber mesh is molded into the exterior surface of the block. 
     
     
         14 . Block in  claim 11  wherein the thermoplastic composite comprises about 5 to 20 weight % glass cenospheres. 
     
     
         15 . The block in  claim 11  wherein the thermoplastic composite comprises about 5 to 15 weight % silica. 
     
     
         16 . The block in  claim 11  wherein the thermoplastic composite comprises about 0.5 to 5 weight % thermoplastic elastomer. 
     
     
         17 . The block in  claim 11  wherein the thermoplastic composite comprises up to about 4 weight % un-melted thermoplastic film components.