Patent Publication Number: US-9410314-B1

Title: Modular floodwall construction elements

Description:
FIELD OF THE INVENTION 
     The present invention relates to construction materials and methods, and more particularly, to a multi-directional, interlocking, hollow modular construction element having flexibility, designed for filling with material such that the active vertical and horizontal pressure of the filling material is utilized to develop a complete closure between adjoining elements. 
     BACKGROUND OF THE INVENTION 
     In building of load-bearing constructions involving filling materials, the active vertical and horizontal pressure of the filling materials is taken into consideration. The active pressure exerted by the filling material is proportional to the height of the filled element. 
     In fly previous patent (U.S. Pat. No. 6,477,814) the stated goal was to “absorb large horizontal or vertical pressure and thus restrain or minimize the effects of active pressure”. In order to do so the patent uses “ . . . rigid hollow polygonal framing elements . . . ”. However, with this approach, water could possibly seep through the hollow cavities comprising the spaces formed between the adjoining rigid elements in this construction, without having anything to stop this and thus, a wall formed by these elements might not function effectively as a water barrier. 
     Therefore, it would be desirable to provide a floodwall construction using construction elements which form a water barrier. 
     SUMMARY OF THE INVENTION 
     Accordingly it is an object of the present invention to provide interlocking elements that can be connected along each face to form a stable, continuous, multi-directional structure, requiring no cement or other adhesive material. 
     In the present invention, the building elements and the hollow cavities comprising the spaces formed between adjacent building elements are filled with any required filling materials, and this combined with the closing of the flexible element walls against adjacent walls becomes an insurmountable barrier to water. 
     The new fast modular method to restrain floods is different from my previous patent (U.S. Pat. No. 6,477,814) since there, the stated goal was to “absorb large horizontal or vertical pressure and thus restrain or minimize the effects of active pressure using rigid hollow polygonal framing elements . . . ” while in this present invention the main goal is to utilize the active pressure in order to create a complete closure between the construction elements. Thus, the present invention uses flexible material for the construction elements (unlike the rigid elements in U.S. Pat. No. 6,477,814), which enables use of the active pressure as a means to achieve complete closure between the construction elements. 
     It is a further object of the present invention to provide flexible elements which are hollow and can be filled with any required materials. 
     It is a further object of the present invention to provide interlocking elements which can take advantage of horizontal pressure arising from the vertical filling material and to use it in order to achieve better closure of the designed system. 
     In accordance with a preferred embodiment of the present invention, there is provided a system of modular interlocking elements comprising a plurality of flexible, hollow, polygonal elements having vertical faces, a first portion of said polygonal elements provided as base elements arranged as a base layer. A second portion of said polygonal elements are provided as interlocking elements arranged as an intermediate layer above said base layer, and a third portion of said polygonal elements are provided as interlocking elements arranged as an upper layer above said intermediate layer. The interlocking elements in said intermediate layer are formed with a vertical slit in all of said vertical faces, and said interlocking elements in said upper layer are formed with vertical slits in at least two of said vertical faces, such that said at least two vertical slits of each of said intermediate layer elements engage said base elements, and said at least two vertical slits of each of said upper layer elements engage said intermediate layer elements, such that said base, upper and intermediate layers provide a mortarless, multidirectional load-bearing construction. 
     The flexible interlocking elements form a continuous structure which utilizes the active pressure exerted by any filling materials. 
     Thus, the load exerted on the flexible element wall develops forces which are used to close the space between the adjacent elements as these forces are spread horizontally to the surrounding foundation. 
     A feature of the present invention is to provide modular elements for use in construction of structures in which active pressure is a factor, such as a water flood protector, causing change in the direction of water flow, enabling construction of small dams, and structures used for personal military position protection (such as an acoustic wall), etc. 
     A further advantage of the present invention is that due to their shape, the inventive construction elements form hollow cavities comprising the spaces formed between adjacent building elements that are filled with filling materials that completely prevent water passage therethrough. 
     A further advantage of the present invention is that the interlocking structure of the elements enables construction in all directions, permitting even load distribution and adding to the load bearing capacity of the entire construction. 
     A further advantage of the present invention is the ability to add elements to the width of the intended structure when it is necessary to strengthen certain areas against water pressure or for any other reason. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a better understanding of the invention with regard to the embodiments thereof, references is made to the accompanying drawings, in which like numerals designate corresponding sections or elements throughout, and in which: 
         FIG. 1  is a general perspective view of three layers of elements with the intermediate layer elements that connect each element and the layers to each other; 
         FIGS. 2A-C  are respectively, perspective, top and elemental views of the modular elements forming a base layer with two rows; 
         FIGS. 3A-C  are respectively, perspective, top and elemental views of the modular elements forming a base layer with three rows; 
         FIGS. 4A-B  are respectively, top views of alternative constructions of the modular elements with three rows with the intermediate layer; 
         FIGS. 5A-B  are respectively, perspective views of the modular elements with three rows forming a base layer and intermediate layer, and three rows forming base, intermediate and upper layers; 
         FIG. 6  is a perspective view of the modular elements with two rows and a partial third row, forming base and intermediate layers; 
         FIG. 7  is a perspective view of the base layer elements; and 
         FIG. 8  is a perspective view of the intermediate and upper layer elements. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  shows a perspective view of a partial assembly of a construction  10 , such as a floodwall, using a series of modular elements  12 . This variation of construction  10  has three layers, a base layer  14 , an intermediate layer  16  and an upper layer  18 . A hollow cavity  17  comprising the space between adjacent elements  12  is formed by the construction. 
     All the variations of elements  12  are shown individually in  FIGS. 7 and 8 , and are denoted as elements  20   a ,  20   b ,  20   c ,  20   d ,  20   e ,  22   a ,  22   b ,  22   c , and  23 , and they all are hollow, having only vertical faces, with no upper or lower horizontal face. 
     The framing elements that form the base layer  14  of construction  10  have five, six, seven or eight smooth vertical faces as can be seen in  FIG. 7  using the polygonal shapes of  20   a ,  20   b ,  20   c ,  20   d , and  20   e  with no vertical slits. 
     In assembling construction  10 , the elements  20   a ,  20   b ,  20   c ,  20   d ,  20   e  of base layer  14  are first arranged in the required formation as can be seen in  FIGS. 2A-B  and  FIGS. 3A-B . 
     As per  FIG. 8 , the alternative embodiment of the modular elements having vertical slits  21  formed on the vertical faces of elements  22   a ,  22   b ,  22   c , and  23  are shown. The slits  21  are formed extending upwards from mid-point of the lower face of the element, for a length one-half the height of the wall. The number of vertical slits  21  formed on the vertical faces of elements  22   a ,  22   b ,  22   c , and  23  may differ as described further below. Element  23  will always have four slits as its main function is to hold together the elements constructing the different layers. The width of the slits  21  are always equivalent to double the thickness of the walls of the elements, to enable the walls of the lower elements to come through up to half the height of the element&#39;s face. Vertical slits  21  are designed to enable a staggered interlocking arrangement of the elements that construct the layers. 
     Each element  23  has four slits  21  and is used for placement over arrangements of the base layer, since its function is to hold the elements tightly together for assembling the construction. Elements  23  hold together the elements in the base layer  14  and provide the intermediate layer  16  for connection to the elements of the upper layer  18 . Elements  23  which are used in intermediate layer  16  do not extend to the outer perimeter of construction  10 . Element  23  is also used in the interior of upper layer  18  in which case element  23  will be surrounded by elements  22   a ,  22   b ,  22   c ,  20   a ,  20   b ,  20   c ,  20   d , or  20   e  located in the outer perimeter. 
       FIGS. 4A and 4B  show construction  10  in which element  23  is arranged upon base layer  14  shown in  FIGS. 2A-B  and  FIGS. 3A-B . Elements  23  each have a slit  21  (see  FIG. 6 ) in each of their four vertical faces. Each element  23  is placed over a group of four elements  24  arranged so as to form a square thus, each slit  21  holds together a side of each of two adjacent ones of four elements  24  and four elements  24  of base layer  14  are held within each intermediate layer element  23 . 
       FIGS. 5A-B  are respectively, perspective views of the modular elements  23  with three rows forming a base layer  14  and intermediate layer  16 , and three rows forming base layer  14 , intermediate layer  16  and upper layer  18 . 
       FIG. 6  is a perspective view of the modular elements with two rows and a partial third row, forming base layer  14  and intermediate layer  16 . 
     Referring now to  FIG. 7  and  FIG. 8 , the individual modular elements are further illustrated. 
       FIG. 7  shows modular elements without slits, these elements comprise the base layer  14  with width of two rows ( FIGS. 2A-B ) or three rows ( FIGS. 3A-B ). 
     When only two rows in width are needed as shown in  FIGS. 2A-B  there will be need of elements  20   a  and  20   d  to construct the structure. If three rows in width or more are needed, additional modular elements  20   b ,  20   c  and  20   e  will be used. 
       FIG. 8  shows modular elements with slits  21  that will have to be used in the intermediate layer and higher. 
     Element  23  in  FIG. 8  shows a modular element having four slits  21  each of which engages the adjacent walls of each of two lower level elements and thus holds four elements together. 
       FIG. 5B  shows how element  23  with four slits holds four elements of base layer  14  at a time, and enables construction of an unlimited structure with two, three or more rows. A second row of elements will have similar elements like the ones of the first row but, will engage slits of element  23  to connect the element to the structure. Elements  22   b  with two slits will be in the corner of the structure (not shown) and element  22   a  with three slits will run in the outer side of the structure (not shown) while element  22   c  with four slits will keep on being in the middle of three rows structure (not shown). 
     The variations in the number of slits and elements enables the various constructions to be formed having a smooth, continuous, outer surface as all outward facing elements have a smooth face and are thus able to divert water flow and protect against water floods. 
     The hollow, flexible elements that make up the structure enables construction  10  to be filled after assembly with filling material, and to use the active pressure generated by the filling material on the flexible walls of side-by-side elements to close the walls against each other on one side, and according to their shape, form hollow cavities  17  comprising the spaces formed between adjacent building elements that are also filled with filling materials that ensure the prevention of water penetration. 
     The interlocking arrangement of the elements results in a stable construction, without need for any mortar or stabilized material, thus increasing the speed and efficiency in which the construction can be erected which is the main goal in case of floods or any other quick need for defense, including an acoustic insulation wall. 
     Having described the invention with regard to certain specific embodiments thereof, it is to be understood that the description is not meant as a limitation, since further modifications will now become apparent to those skilled in the art, and it is intended to cover such modifications as fall within the appended claims.