Building block

Molded composite polymer construction blocks are made that are easily assembled, using alinement pins and apertures, with channels for insertion of sealant and vertical passageways for pipes, wires, etc. Stud supporting cavities in one side of the block extend into the ribs or end walls. The cavities can be provided with a protective metal insert. Studs or wooden blocks can be inserted into the cavities. The wooden studs or wooden blocks of various lengths provide spacing for insulation and/or drywall installation.

BACKGROUND OF THE INVENTION

1. Field of the Invention

A building block can be made of a polymer and includes alinement pins and apertures for stack formation, a channel, for non-binding sealant, a cavity that can be metal reinforced, for studs or wood used as spacers for insulation and/or supporting dry wall, and central passageways, for routing pipes, wires, etc.

2. Description of Related Art

SUMMARY OF THE INVENTION

A waterproof building block is formed by molding a composite polymer concrete, such as Quazite™, so as to have alinement pins and apertures on the upper and lower surfaces. Horizontal and vertical channels are provided in the block for reception of a sealer. Internal vertical openings provide for passage of pipes, wires, HVAC tubes, etc. A central cavity is provided in one side of the block and extends into the block central rib or end walls. A vertical central rib can be provided with a protective metal insert for reception of a removable stud or a wooden block that can be used to form a spacing for insulation and/or dry wall attachment. A composite polymer concrete is composed of a fiber reinforced polymer composite material using a resin binder, aggregate and possible fillers.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A waterproof building block is provided that can be manufactured from resin binder, chopped glass fibers, and open graded aggregate of less than ¾″. The block is preferably  composed of a cast polymer base fiberglass reinforced block with steel alinement pins and a cavity into which a wooded stud can be inserted for fabricating a wooded framed wall. The block can be colored and formed with decorative coverings to resemble siding, brick, stucco, etc. The lightweight blocks are strong enough to compete with conventional concrete blocks and can be assembled and disassembled and recycled easily, as no mortar or permanent joining means are necessary.

The construction block can be formed with one unfinished side and three finished sides for use as a decorative covering, eliminating the need for decorations and mortar. It can be used as a load bearing wall framework to support dry wall or sheet rock, etc. When the blocks are alined, unobstructed inside passages through the blocks provide for running electrical conduits, utility piping, etc.

As seen inFIGS. 1 and 2, the building block1can be constructed from a fiber reinforced polymer composite using resins and aggregate5. The blocks have a finished front wall2, unfinished back wall4, and finished end walls3and a central rib19. The blocks contain vertical13and horizontal14channels for the introduction of a non-binding sealant that will permit ease of recycling when the blocks are disassembled. The horizontal channel extends around the upper surface along the ends and front of the upper surface. The seals waterproof the wall the blocks are used to construct. Plural steel or plastic alinement pins8and matching apertures9are provided, preferably in the channels, so that the blocks can be  accurately placed on each other by even a novice in the art. The pins and apertures provide the means for both rapid assembly and rapid disassembly. With the blocks in alinement one layer over the other, open passages15, essentially in vertical alinement with each other, whether staggered or not, provide a passage for equipment such as pipes, wires, HVAC, etc. The outer vertical surfaces can be finished6or unfinished4. The finished surfaces can be textured by various designs in molding plates. The outer walls18and central rib19define the open passages15. A vertically elongated central recess or locking cavity21is made through the unfinished side and into the wide central rib19. The cavity21is narrower than the width of the central rib19, and extends within the central rib without communication with the open passages15. The inner surfaces of the central recess21are spaced from the upper surface and from the lower surface to provide support and can be covered by a metallic insert22. The metal insert is preferably bonded into the block by a resin binder and interlocking spikes23. The metallic insert distributes forces to the building block side and central rib synthetic material to preclude wear and tear due to localized forces that could easily damage the synthetic material. The metallic insert22is provided with interlocking spikes23, punched out from the insert, and removable stud mounting holes24, formed in the insert. The metallic insert is the recipient of a spacing member in the form of either a wooden block25or a plastic or metal removable preformed stud insert20. The wooden block25has an upper surface27and end surface26. The removable stud20is in the shape of a “U” with a base29and legs11extending out from the base. The legs of the removable stud are provided with protrusions28. The removable studs can be held in the metallic insert22by having the protrusions28inserted into the stud mounting holes24. The wooden block25can be held within the metallic insert22by having the wooden block impaled by the interlocking spikes23. By choosing the appropriate length wooden block25, any desired thickness of insulation can be placed between drywall, or other finishing material attached to or abutting against the outer ends26of the wooden blocks or the stud inserts, and the blocks. The wooden blocks25can be secured in the central rib19by providing a pin hole7through the central rib19and metallic insert22and a pin hole32in the wooden block25for placement of a retainer pin. Depending on the strength of the construction material5, there may be no need for the metallic insert22.

FIG. 3depicts building blocks assembled into a three tier wall. The bottom and top tiers show wooden blocks25inserted into the locking cavities21on the unfinished face4of the blocks. A tie down bolt31passes through plates30and passages15in the blocks to secure the wall in place. The wooden blocks provide a space between the block face4and the wooden block end surface26that can be used to position insulation between the blocks and a dry wall secured to or spaced by the end surfaces of the wooden blocks.

The block40shown inFIG. 4is similar to that shown inFIG. 1with the recess or cavity41placed in a wide end wall43. The same front wall2, end walls3, vertical13and horizontal14channels and open passages15are present. The unfinished back wall44accommodates the cavity41with a thin central rib49.

The block50shown inFIG. 5is similar to that shown inFIG. 4with two cavities51,52placed in wide end walls53,55. The cavities51,52are formed in the unfinished back wall54. The same end walls3, front wall2, vertical13and horizontal14channels, and open passages15are present. The central rib49, as inFIG. 4, is provided.

The block60shown inFIG. 6is similar to that shown inFIG. 1but is provided with two wide central ribs63,64and three open passages65. The wide central ribs63,64each house a cavity61,62formed in the unfinished back wall66. The block60is provided with the same front wall2, end walls3, vertical13and horizontal14channels. As with the other cavities, the wide end walls and/or wide central ribs surround the cavities to secure the wooden or other blocks securely in place.

The block70shown inFIG. 7has the same end walls3, front wall2, vertical13and horizontal14channels as inFIG. 1. The central section of the block has a wide rib73at the front that expands in width and depth74until it can accommodate a cavity71that has a horizontal elongated width for receiving a wooden block25in the back wall76. The cavity71can be made in the unfinished back wall at any desired angle.

It is believed that the construction, operation and advantages of this invention will be apparent to those skilled in the art. It is to be understood that the present disclosure is illustrative only and that changes, variations, substitutions, modifications and equivalents will be readily apparent to one skilled in the art and that such may be made without departing from the spirit of the invention as defined by the following claims.