Patent Publication Number: US-2023160199-A1

Title: Interlocking building blocks and mortarless interlocking building system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. Pat. Application Serial No. 17/133,959 filed Dec. 24, 2020 which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The present invention relates to building blocks for a mortarless interlocking building system. 
     BACKGROUND 
     Compressed earth bricks and fired bricks have 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, concrete 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 creates 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 desirable. 
     SUMMARY 
     In one aspect, the present 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 concrete blocks in many metrics including strength, crack resistance, 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 all other systems due to the fact that it interlocks on all sides allowing for unmatched structural strength and versatility. 
     In one aspect, the present 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 all six sides with other interlocking components. In another aspect, adhesives can optionally be used to adhere 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 present invention are stronger than concrete blocks and provide excellent resistance to water, insects, mould/mildew, storms, and high wind. Bricks according to embodiments of the present invention are environmentally friendly, less expensive to build with than wood or concrete, and require little maintenance. Bricks according to embodiments of the present 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 present 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 present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein: 
         FIG.  1    is a perspective view of three building blocks according to embodiments of the present invention; 
         FIG.  2    is a top view of a building block according to another embodiment of the present 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 present 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 present 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 present invention; 
         FIG.  10    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 present 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 present 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 present 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 present invention; and, 
         FIG.  18    is a flow diagram of a method of manufacturing components of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to  FIG.  1   , in one embodiment, the present invention relates to.a six sided interlocking construction block (and corresponding interlocking components) produced 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 &amp; 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 cut, screwed and drilled with less effort than traditional concrete blocks and without the nuisance of cracks and chips. 
     Referring initially to  FIG.  2    to  FIG.  4   , in another embodiment, the present invention relates to an interlocking building system which includes building blocks that interlock on all 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  1  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 concrete 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 lateral 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  11 , 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 integration, or any other integration with the corresponding interlocking system. 
     Referring to  FIG.  9   , the building blocks according to embodiments of the present invention can be shorter or longer than the building blocks described with reference 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 elements of the block  50  and block  60  parallel those of block  2  which is described above with reference 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 resistant seal. 
     A building block according to another embodiment of the present invention is illustrated in  FIG.  12    to  FIG.  15   . The building block has the same elements 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 present 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 present invention do not require cutting, and adhesives are optional, depending on the application. Systems of the present 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 present 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 present invention. 
     The present 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 temperature 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 present system may require. The heated mixture is cooled naturally and/or artificially. 
     Systems of the present invention can also be adapted to be easily incorporated into autonomous construction. 
     Building components according the embodiments of the present invention can be made from a composite material including of a wide range of recycled thermal plastics, including but not limited to PE, PET, and PS which are ground to about ¼ inch particles and then blended with other ground up waste aggregates, including but not limited to, recycled concrete, brick, and/or glass. UV inhibitors and fire inhibitors as well as stabilizing agents can be added as they are needed (up to 10%). In embodiments of the present invention, the building blocks are solid other than for the conduits discussed above. 
     The present 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 temperature 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 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 present system may require. The heated mixture is cooled naturally and/or artificially.