Patent Publication Number: US-6907703-B2

Title: Interlocking block

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The field of the present invention is interlocking building blocks and/or containers. 
   2. Background 
   Building blocks with interlocking features are known from the disclosures of U.S. Pat. Nos. 6,234,721, 6,205,735, and 5,107,653. Such interlocking building blocks facilitate the assembly of and provide additional stability to walled structures. However, the versatility of such blocks is typically limited by the design of the interlocking features. Thus, for most interlocking blocks, unless additional types of blocks or other components are introduced, only straight walls may be built. 
   Containers are also designed to be interlocking and stackable, one upon another, in order to facilitate storage and transportation, create additional stability, and optimize the use of space. Examples of such containers are disclosed in U.S. Pat. No. 5,167,336, and U.S. Design Pat. Nos. D349,046 and D447,944. Such containers are primarily useful for the aforementioned reasons, or alternatively as building block toys for children after serving their primary function. Outside of these applications, such containers have little practical use and therefore little value. 
   SUMMARY OF THE INVENTION 
   The present invention is directed towards interlocking blocks. Each interlocking block comprises five sides, each side defining a planar interface. At least one side of the interlocking block is adapted to engage the same relative side of another like interlocking block. 
   In a first separate aspect of the present invention, the first side of a first interlocking block includes an elongated protrusion extending therefrom and a protrusion receptacle. The elongated protrusion of each block is adapted to engage the protrusion receptacle of a second similar block to interlock the two blocks. Thus, the elongated protrusion of the second block also engages the protrusion receptacle of the first block. To better interlock the two blocks, the protrusion receptacle may intersect a fastener receptacle on one of the other sides. The combination of the protrusion receptacle and the fastener receptacle form an interior passageway from the first side to the other side. When interlocked with such a configuration, the elongated protrusion extends through the interior passageway and may be secured with a fastener that is adapted to prevent the elongated protrusion from receding through the interior passage. 
   In a second separate aspect of the present invention, the second side of the interlocking block includes at least one flange and one flange receptacle. The flange and flange receptacle are adapted to engage the flange receptacle and flange, respectively, on the second side of a second similar block to interlock the two blocks. The second side of the interlocking block may also include at least two anti-shear receptacles which are adapted to receive shear prevention components. The anti-shear receptacles provide versatility in the manner the interlocking block may be combined with other similar interlocking blocks. For example, the sides of two interlocking blocks, each side including anti-shear receptacles, may be juxtaposed such that the anti-shear receptacles of each block are aligned with those of the other block. Shear prevention components having a depth greater than any one of the anti-shear receptacles may be inserted into the anti-shear receptacles. Thus, the shear prevention components will prevent the each block from sliding in a lateral direction relative to the other block. 
   In a third separate aspect of the present invention, the third side of the interlocking block includes at least one flange and one flange receptacle. The flange and flange receptacle are adapted to engage the flange receptacle and flange, respectively, on the third side of a second similar block to interlock the two blocks. 
   In a fourth separate aspect of the present invention, the second side of the interlocking block includes at least two ant-shear receptacles which are adapted to receive shear prevention components. The anti-shear receptacles provide versatility in the manner the interlocking block may be combined with other similar interlocking blocks as described further herein. 
   In a fifth separate aspect of the present invention, the second side of the interlocking block includes at least two ant-shear receptacles which are adapted to receive shear prevention components. The anti-shear receptacles provide versatility in the manner the interlocking block may be combined with other similar interlocking blocks as described further herein. 
   In a sixth separate aspect of the present invention, the five sides define an interior space of the interlocking block and the block includes an opening which allows the interior space act as storage for appropriate material, such as liquids, granular solids, or other form of particulate material, e.g., rice, corn, sugar, and salt. Such a block thus has a dual use as an interlocking block and as a storage container. 
   In a seventh separate aspect of the present invention, any of the foregoing aspects may be employed in combination. 
   Accordingly, it is an object of the present invention to provide an improved interlocking block and container. Other objects and advantages will appear hereinafter. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings, wherein like reference numerals refer to similar components: 
       FIG. 1  illustrates a plan view of an interlocking container; 
       FIG. 2  illustrates a sectional view of the interlocking container along the line  2 — 2  of  FIG. 1 ; 
       FIG. 3  illustrates a sectional view of the interlocking container along the line  3 — 3  of  FIG. 1 ; 
       FIG. 4  illustrates two interlocking containers configured in a first orientation with the first sides engaged; 
       FIG. 5  illustrates two interlocking containers configured in a second orientation with the second sides engaged; 
       FIG. 6  illustrates two interlocking containers configured in a third orientation with the third sides engaged; 
       FIG. 7  illustrates two interlocking containers configured in a fourth orientation with the third sides rotatably engaged; 
       FIGS. 8A-E  illustrate the rotational interaction of the flange and flange receptacle in the configuration of  FIG. 7 ; 
       FIG. 9  illustrates two interlocking containers configured in a fifth orientation with the third sides engaged; 
       FIG. 10  illustrates two interlocking containers configured in a sixth orientation with the anti-shear receptacles of the fourth and fifth sides aligned; 
       FIG. 11  illustrates two interlocking containers configured in a seventh orientation with the anti-shear receptacles of the second and fifth sides aligned; and 
       FIGS. 12A-E  illustrate examples of structures which may be formed using a plurality of interlocking containers. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Turning in detail to the drawings,  FIG. 1  illustrates an interlocking container  10 , showing all five sides of the container in plan view. As can be seen from the figures, the five sides, when assembled, form a pentahedron. The container  10  is constructed from a recycled plastic, a material that is both light weight and durable. The first side  100  of the container  10  includes a substantially planar portion  101  that defines the planar interface between two interlocking containers when the first sides are engaged. An elongated protrusion, shown as a spout  102  in the figures, extends outward from the planar portion  101  at an acute angle. The spout  102  is formed in the shape of the top portion of a plastic beverage container, and is sealable by the container cap  106 . A spout receptacle  104  extends inward from the planar portion  101  in the opposite direction of the spout  102 . The angle of the spout receptacle  104 , relative to the planar portion  101 , is the same as the acute angle between the spout  102  and the planar portion  101 . The overall shape of the spout receptacle  104  is complimentary to the shape of the spout  102 , the spout receptacle  104  having the same general shape as the spout  102  and being appropriately sized so that the spout  102  of a second interlocking container may be inserted therein when the first sides of the two containers are engaged as shown in FIG.  4 . The spout  102  and the spout receptacle  104  are illustrated in profile in FIG.  3 . 
   The second side  200  of the container  10  includes a substantially planar portion  201  that defines the planar interface between two interlocking containers when the second sides are engaged. A flange  202  and a flange receptacle  204  are disposed on opposite sides of the second side  200 . The flange  202  extends outward from the second side along the entire width of the container, while the flange receptacle  204  extends inward therefrom along the entire width of the container. The shape of the flange  202  is complimentary to the shape of the flange receptacle  204 . 
   Referring to  FIG. 3 , the flange  202  comprises a cylindrical body  208  and an arm  210  that extends radially from and along the entire length of the cylindrical body  208 . The arm  210  affixes the flange  202  to the second side  200 . The overall diameter of the cylindrical body  208  is greater than the width of the arm  210 . The flange receptacle  204  comprises a constricting portion  214  that broadens out into a cylindrical opening  212 . The constricting portion  214  is appropriately sized to accept the arm of a flange from a second interlocking container while at the same time being smaller than the overall diameter of the cylindrical body. The cylindrical opening  212  is appropriately sized to axially accept the cylindrical body of a flange from a second interlocking container. 
   Returning to  FIG. 1 , the second side  200  further includes two pair of anti-shear receptacles  206   a ,  206   b . Both pair of anti-shear receptacles  206   a ,  206   b  are symmetrically located and spaced to be alignable with either the anti-shear receptacles  502  on the fifth side of an interlocking container or the anti-shear receptacles  402  on the fourth side of an interlocking container when the first sides of the containers are engaged as shown in FIG.  4 . Shear prevention components, discussed in further detail below, are insertable into the anti-shear receptacles to help stabilize the relative position of two containers when the anti-shear receptacles of the two containers are aligned side-by-side. 
   The third side  300  of the container  10  includes a substantially planar portion  301  that defines the planar interface between two interlocking containers when the third sides are engaged. Two flanges  302 ,  303  are disposed on opposite corners of the third side  300 , and two flange receptacles  304 ,  305  are disposed on the other two opposite corners. A shoulder  306  is disposed near each flange  302 ,  303  to help align the flanges  302 ,  303  with the flange receptacles  304 ,  305  when engaging the third sides of two interlocking containers and provide additional stability when the third sides of two interlocking containers are engaged. The shoulders  306  extend from the main body of the container the same distance as the flange receptacles  304 ,  305 , thus enabling the container stand upright on the third side  300  and remain level when placed on a horizontal surface. 
   As shown in  FIG. 8A , the flange  302  comprises a cylindrical body  320  and a radially extending arm  322  to affix the flange  302  to the third side  300 . The arm  322  does not extend axially to the ends of the cylindrical body  320 . The overall diameter of the cylindrical body  320  is greater than the width of the arm  322 . The second flange  303  is the same as the flange  302  just described. The flange receptacle  304  comprises a block  323  with two pairs of outward extending fingers  324 ,  326 . The two pairs of fingers  324 ,  326  are separated by a distance that is at least equal to the axial length of the arm of a flange  322 . Each finger is appropriately curved so that each pair of fingers  324 ,  326  forms a cylindrical opening  328  and maintains axial alignment between the cylindrical body  320  and the cylindrical opening  328  when the flange  302  is inserted into the flange receptacle  304 . The second flange receptacle  305  is the same as the flange receptacle  304  just described 
   Returning to  FIG. 1 , the third side  300  further includes a fastener receptacle  308 . As shown in  FIG. 3 , the fastener receptacle  308  intersects the spout receptacle  104  to form an interior passageway  310  through the container. The interior passageway  310 , the end portion of the spout  102 , and the container cap are all relatively sized so that the end portion of the spout  102  may pass through the interior passageway  310  but the container cap  106  may not pass therethrough. Thus, as shown in  FIG. 4 , when the first sides of two interlocking containers  10   a ,  10   b  are engaged, the spouts  102   a ,  102   b  of each container extend through the interior passageways of the opposite container  310   b ,  310   a  and are secured with the corresponding container caps  106   a ,  106   b.    
   The fourth side  400  of the container  10  includes a substantially planar portion  401  that defines the planar interface between two interlocking containers when the fourth side is adjacent either the second, fourth, or fifth side of the second container. The fourth side  400  further includes two anti-shear receptacles  402 . The fifth side similarly includes a substantially planar portion  501  and two anti-shear receptacles  502 . As shown in  FIG. 2 , the anti-shear receptacles  402 ,  502  have the same relative location and spacing on the fourth and fifth sides, respectively. Thus, as shown in  FIG. 10 , when the fifth side of a first container  10   a  is substantially adjacent the fourth side of a second container  10   b , the anti-shear receptacles  502   a ,  402   b  are aligned. Shear prevention components are insertable into the anti-shear receptacles of the fourth and fifth sides to help stabilize the relative position of two containers when anti-shear receptacles of the two containers are aligned. 
   As discussed above,  FIG. 4  illustrates two interlocking containers  10   a ,  10   b  with identical first sides engaged. When engaged thusly, all other sides of each container may be engaged with yet another interlocking container. 
     FIG. 5  illustrates two interlocking containers  10   a ,  10   b  with the second sides engaged. The second sides are engaged by aligning the cylindrical body of each container&#39;s flange  202   a ,  202   b  with the cylindrical opening of each container&#39;s flange receptacles  204   b ,  204   a  and sliding the containers in opposite directions parallel to the axial lines defined by the cylindrical bodies until the second sides are substantially aligned. In this configuration, all other sides of each container may be engaged with yet another interlocking container. 
     FIG. 6  illustrates two interlocking containers  10   a ,  10   b  with the third sides engaged. The flanges and flange receptacles on the third side of the first container  10   a  engage the flange receptacles and flanges, respectively, on the third side of the second container  10   b . The third sides are engaged in this configuration by orienting the two interlocking containers accordingly with the cylindrical bodies of the flanges aligned with the cylindrical openings of the flange receptacles and sliding the containers in opposite directions parallel to the axial lines defined by the cylindrical bodies until the third sides are substantially aligned. In this configuration, all other sides of each container may be engaged with another interlocking container. 
     FIG. 7  illustrates two interlocking containers  10   a ,  10   b  with the third sides rotatably engaged. Only one flange and one flange receptacle on the third side of the first container  10   a  engage one flange receptacle and one flange, respectively, on the third side of the second container  10   b .  FIGS. 8A-E  illustrate how the flange and flange receptacles are rotatably engaged. A loose tolerance exists between the tips of the fingers  324  on the flange receptacle  304  and the arm  322  on the flange  302  to permit engagement of the flanges and flange receptacles as shown in FIG.  7 . In this configuration, the first, fourth, and fifth sides of each container may be engaged with another interlocking container. 
     FIG. 9  illustrates two interlocking containers  10   a ,  10   b  with the third sides engaged in yet another orientation. The flanges and flange receptacles on the third side of the first container  10   a  engage the flange receptacles and flanges, respectively, on the third side of the second container  10   b . This engagement is achieved in the same manner described in association with the configuration illustrated in FIG.  6 . In this configuration, all other sides of each container may be engaged with another interlocking container. 
     FIG. 10  illustrates two interlocking containers  10   a ,  10   b  with the fifth side of the first container  10   a  substantially aligned with the fourth side of the second container  10   b . The anti-shear receptacles of the two sides are aligned and a shear prevention component  15  is disposed in the space formed by the adjacent anti-shear receptacles  402   b ,  502   a . The shear prevention component  15  may be any appropriate material that is at least semi-rigid and can be adapted to fit in the space formed by two anti-shear receptacles. The shear prevention component  15  has a height which spans the combined depths of the two anti-shear receptacles. Although a height that is at least greater than the depth of any single anti-shear receptacle is sufficient, greater stability is achieved when the shear prevention component  15  fills a greater amount of the space formed by two anti-shear receptacles. In the configuration of  FIG. 10 , all other sides of each container may be engaged with another interlocking container. 
     FIG. 11  illustrates two interlocking containers  10   a ,  10   b  with the anti-shear receptacles  502   a  on the fifth side of the first container  10   a  aligned with the anti-shear receptacles  206   b  on the second side of the second container  10   b . Shear prevention components  15  are disposed in the spaces formed by the aligned anti-shear receptacles. In this configuration, the first container  10   a  may be engaged with another interlocking container on the first, second, third, and fourth sides, and the second container  10   b  may be engaged with another interlocking container on the first, third, fourth, and fifth sides. 
     FIGS. 12A-E  illustrate some of the different structures that may be formed using the interlocking container described herein. In forming such structures, additional structural integrity is added when appropriate by filling the containers with granular solids such as sand. Other fill may also be used, however, a granular solid is preferred because such fill is easy to work with and reduces the chance that the structure will lose integrity and collapse under its own weight. 
     FIG. 12A  illustrates a planar wall  20  that may be built using the interlocking configuration shown in FIG.  4 . Each horizontal layer of interlocking containers in the wall are connected using the configurations shown in  FIGS. 9 and 10 .  FIG. 12B  shows walls  20  that may be built to form an enclosure with a hinged door  22 . Each individual wall and the door are formed using the interlocking configurations shown in  FIGS. 4 and 10 . Each wall is connected at the corners to another wall using the interlocking configuration shown in FIG.  7 . The door  22  is rotatably connected to the wall using the interlocking configuration shown in FIG.  7 . 
     FIG. 12C  illustrates a roof structure that may be constructed using interlocking containers. This structure is formed by connecting interlocking containers in the configurations shown in  FIGS. 5 ,  6 , and  9 . The roof thus formed may be set on top of and connected to the walls of  FIG. 12B  using the interlocking configuration of FIG.  11 . 
     FIG. 12D  illustrates a second roof structure that may be constructed using interlocking containers. This structure is formed by connecting interlocking containers in the configurations shown in  FIGS. 4 ,  5 ,  6 , and  9 . The roof thus formed may be set on top of and connected to the walls of  FIG. 12B  using the interlocking configuration of FIG.  11 . 
     FIG. 12E  illustrates a wall with curves that may be constructed using interlocking containers. The planar portion of the wall is formed using the interlocking configuration shown in  FIGS. 4 ,  9 , and  10 . The curved portion of the wall is formed using the interlocking configuration shown in  FIGS. 4 ,  7 , and  10 . Those skilled in the art will recognize that other forms of structures may be built using the interlocking configurations described herein. 
   Thus, an interlocking block is disclosed. While embodiments of this invention have been shown and described, it will be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. For example, while the embodiment disclosed comprises and interlocking container, those skilled in the art will recognize that the interlocking block may be solid throughout or have any other appropriate internal structure. By way of further example, the interlocking containers described and illustrated in the figures are constructed from recyclable plastics. Such plastics are frequently used to bottle consumables like water and carbonated drinks. Thus, portions of the illustrated interlocking containers take the form, or portions thereof, of the recycled materials used for construction. The interlocking containers described herein, however, may be constructed from a wide range of alternative materials. When constructing an interlocking block from alternative materials, the shape or form of most features described and illustrated herein may be altered without diverging from the basic principles of the invention. The invention, therefore, is not to be restricted except in the spirit of the following claims.