Patent Publication Number: US-11391041-B2

Title: Unibody structural frame for an interlocking structural block, an interlocking structural block, and a system of interlocking structural blocks

Description:
This application claims priority to U.S. Provisional patent application Ser. No. 62/740,849 filed Oct. 3, 2018. 
    
    
     BACKGROUND 
     There are various building blocks used in construction of buildings in the prior art, which include self-alignment pins or included reinforcement means. We refer the reader some prior patent applications of this inventor as examples: CA 2899473; CA 2899465; CA 2899476 and U.S. Ser. No. 14/815,836. 
     Generally, the prior art over which the invention is an improvement include blocks made of a matrix material which surround embedded elements, the elements which provide one of: compression load-bearing reinforcement; self-alignment of blocks when stacked into courses to form a panel; or post-tensioning anti-deformation means embedded within a panel formed of the blocks. Other examples of prior art include walls formed of stacked cinder blocks into cavities of which reinforcements may be inserted and cement or some other strengthening material may be poured. 
     The invention disclosed here provides improvements over this prior art. 
     SUMMARY 
     The frames are each embedded within a matrix of material which forms a construction block for assembly at a site into a wall or other panel. The frames provide interlocking elements within the wall or other panel, while the matrix material may be tailored to provide insulation, fire resistance, waterproofing, or some additional or other functionality to the wall or panel, and hence to the building being constructed using the blocks with these frames. 
     In accordance with a broad aspect of the invention, there is provided a unibody structural frame for an interlocking structural block comprising a plurality of struts connected with a web, each strut having a top portion, an outer surface, and an inner surface, wherein each strut is configured for engagement within a recess of the strut of another unibody structural frame, the web holding the struts in relative rigid spacial symmetry and thus preventing the struts from rotation or translation about any axis with respect to any other strut attached to the web; an opening at the bottom end of each strut, the opening configured for engagement with the top portion of the outer surface of a strut of an adjacent structural block; a plurality of webs extending in a first direction, each web having a first end and a second end, wherein each web is connected to one or more struts; and a plurality of webs extending in a substantially orthogonal direction to the first direction, each web having a first end and a second end, wherein each web is connected to one or more of the struts. 
     In accordance with another broad aspect of the invention, there is provided an interlocking structural block comprising a block body having opposed top and bottom surfaces, opposed side surfaces and opposed end surfaces; and a unibody structural frame embedded within the block body, one end of the unibody structural frame flush with the bottom surface and an opposite end of the unibody structural frame extending through the top surface of the block body. 
     In accordance with another broad aspect of the invention, there is provided a system of interlocking structural blocks comprising a plurality of interlocking structural blocks connected through one or more struts of one block to one or more struts of an adjacent block. 
     It is to be understood that other aspects of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein various embodiments of the invention are shown and described by way of illustration. As will be realized, the invention is capable for other and different embodiments and its several details are capable of modification in various other respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive. 
     Some advantages of the present invention are that the components may be manufactured and assembled in a factory, which allows for prefabrication under controlled systems using automated equipment. This avoids idiosyncratic assembly errors on-site. This permits less waste; stronger, faster and more accurate installation of walls and other panels; and use of less skilled labour. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A further, detailed, description of the invention, briefly described above, will follow by reference to the following drawings of specific embodiments of the invention. These drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. In the drawings: 
         FIG. 1  is a perspective top view of a unibody structural frame. 
         FIG. 2  is a perspective bottom-view of a unibody structural frame. 
         FIG. 3  is a perspective bottom view of an interlocking structural block. 
         FIG. 4  is a perspective top view of an interlocking structural block. 
         FIG. 5  is a top view of a unibody structural frame. 
         FIG. 6  is a perspective sectional view of a unibody structural frame. 
         FIG. 7  is a cross sectional view of a unibody structural frame. 
         FIG. 8  is a cross sectional view of a unibody structural frame. 
     
    
    
     FIGURE LABELS 
       100  Unibody Structural Frame 
       110  Strut 
       111  Strut Recess 
       112  Strut Top Portion 
       113  Spacer Rib 
       120  Web 
       130  Mold Locks/Overhanging ribs 
       140  Standoffs 
       200  Block Body 
       210  Conduit Holes 
       300  Interlocking Structural Block 
       400  System of Interlocking Structural Blocks 
     DESCRIPTION OF VARIOUS EMBODIMENTS 
     The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the present invention and is not intended to represent the only embodiments contemplated by the inventor. The detailed description includes specific details for the purpose of providing a comprehensive understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without these specific details. 
     The invention provides a unibody structural frame  100  for an interlocking structural block  300 . The unibody structural frame has a plurality of struts  110  connected with a web  120 , each strut having a top portion  112 , outer surface and an inner surface and struts may be hollow tubes or cylinders. Each strut is configured for engagement within a recess  111  of the strut of another unibody structural frame. The web holds the struts in relative rigid spacial symmetry and thus prevents the struts from rotating about any axis with respect to any other strut attached to the web. There is an opening at the bottom end of each strut configured for engagement with the top portion of the outer surface of a strut of an adjacent structural block. The unibody structural frame further includes a plurality of webs  120  that extend in a first direction as a vertical elongated flat part from the bottom of the interlocking structural frame. Each web has a first end and a second end, wherein each web is connected to one or more struts. The unibody structural frame has another plurality of webs extending in a substantially orthogonal direction to the first direction, each web having a first end and a second end, wherein each web is connected to one or more of the struts. 
     In one embodiment, the strut is a hollow shell, having one or more side surfaces, an aperture in the bottom surface, and a top portion with or without an aperture in the top portion. 
     In one embodiment, the top portion of a strut engages with a stepped portion of the bottom of another strut of an adjacent structural block. Where there is an aperture in the top portion, tension means may be placed between the blocks. 
     In one embodiment, the webs locate and lock the struts relative to each other in both translation and rotation. 
     In one embodiment, the struts and webs are formed simultaneously during the manufacturing process. 
     In one embodiment, spacer ribs  113  are included along the inner surface of the strut for alignment and adhesive spacing. 
     In one embodiment, there are overhanging ribs  130 , or mold locks, on the side surfaces of the webs. 
     In one embodiment, standoffs  140  are formed on opposing ends of the unibody structural frame. 
     In one embodiment, the plurality of struts, one or more webs, and one or more side surfaces are formed from one or more of: metallic materials, iron, steel, stainless steel, polymeric materials, silicone rubber, polyethylene, acrylic resins, polyurethane polypropylene, polymethylmethacrylate, synthetic and natural biodegradable polymers, biopolyesters, agro-polymers, copolymers, fiber reinforced plastics, composites, wooden materials, or any combination thereof. 
     In one embodiment, the interlocking structural block has a block body  200  with opposed top and bottom surfaces, opposed side surfaces and opposed end surfaces. The block body includes a unibody structural frame  100  embedded within the block body, one end of the unibody structural frame flush with the bottom surface and an opposite end of the unibody structural frame extending through the top surface of the block body. 
     In one embodiment, the struts are substantially square in cross section. 
     In one embodiment, the block body further includes one or more conduit voids  210  for accommodating electrical wiring, piping or utilities. In such an embodiment, the unibody structural frame further includes a ring to align with each conduit. The ring may be held to the web with small attachment elements, which also are designed to hold the block body material from falling through the frame prior to the body material being fully cured. 
     The invention further provides a system of interlocking structural blocks  400 . The system includes a plurality of interlocking structural blocks  300  connected through one or more struts of one block to one or more struts of an adjacent block. 
     In one embodiment, the engagement of struts from adjacent unibody structural frames are joined together and fixed in place relative to each other through an adhesive agent. 
     In one embodiment, the adhesive agent includes one or more of epoxy, acrylic, cyanoacrylate, urethane, or silicone. 
     In one embodiment, the adjacent surfaces of two block bodies are joined together through the use of a mortar agent. 
     In one embodiment, the mortar agent includes one or more of lime mortar, polymer based agent, cement, or plaster. 
     In one embodiment, the interlocking structural block is used in the manufacture of a panel or wall structure. 
     In one embodiment, the interlocking structural block is used in the manufacture of a column or beam. 
     The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to those embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein, but is to be accorded the full scope consistent with the claims, wherein reference to an element in the singular, such as by use of the article “a” or “an” is not intended to mean “one and only one” unless specifically so stated, but rather “one or more”. All structural and functional equivalents to the elements of the various embodiments described throughout the disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the elements of the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims.