Abstract:
A mortarless interlocking building block for a building block system comprising a single light-weight block of the standard building block dimensions molded from plastic and configured to be separable into three-quarter, half and one-quarter sizes for accommodating prescribed wall dimension lengths and openings, including a feature for building interconnecting right-angle walls.

Description:
The present invention relates to an improved building block for a mortarless interlocking building block system, and more particularly to an improved block that may be easily sized at construction sites to accommodate wall lengths and openings in walls. 
   BACKGROUND OF THE INVENTION 
   Heretofore, it has been well known in building block systems to provide interlocking and mortarless building blocks for load-bearing and non-load-bearing walls such that multiple blocks may be assembled in courses and stacked without the use of mortar. 
   It has also been known to provide standard building blocks made of plastic for constructing courses and stacks of courses to form a wall or walls. Such blocks have included connecting elements at opposite ends and intermeshing connecting members at the top and bottom faces of the blocks. It has also been known that such blocks have self-aligning features because of male and female connectors, as well as interengaging parts for aligning stacked courses of staggered blocks. 
   It has been long recognized that use of mortarless interlocking blocks without the need of mortar results in rapid construction of walls even when using unskilled labor. 
   It has also been known to provide mortarless interlocking products in a system which includes and requires a stretcher block for the erection of a wall, corner blocks for defining the intersection of two walls at right angles, and multiple lengths of blocks for accommodating specified longitudinal dimensional courses of blocks. Further, heretofore it has been known to provide corner blocks of various lengths in order to size a wall along a particular course. 
   Most heretofore known blocks for mortarless interlocking block systems to produce walls have been costly to produce and in many cases grooves or sockets and protrusions or connectors have been cut into the blocks after they have been molded. Such prior known blocks require additional finishing such as by grinding or cutting to provide connections, and to meet required tolerances. Some heretofore known block systems have also included L-shaped corner blocks in order to erect walls perpendicular to each other. 
   The improved block of the present invention overcomes the difficulties and problems in heretofore known blocks for block systems by providing a single light-weight block of molded plastic which can easily be cut at the job site to accommodate various course lengths and provide for openings needed for windows and/or doors, as well as eliminating the need to have several types of blocks and various sized blocks to erect a block wall for a building. 
   SUMMARY OF THE INVENTION 
   Accordingly, the improved block of the present invention improves the adaptability for erecting a wall of building blocks in a building block system as well as providing the required strength of a wall, and providing the lowest possible cost of erecting such walls. The improved block of the invention is injection molded from a suitable plastic resin such as a urethane or polypropylene and configured so that it can be easily molded and released from the forming mold while preserving full detail and obviating any subsequent reshaping or refinishing before it is to be used. Suitable additives may be included in the plastic resins, such as a UV inhibitor. While the building block of the invention is primarily useful for building external walls of buildings, it should be appreciated that it can be fabricated in various sizes in order to accommodate various requirements for wall constructions including inside walls. 
   While the improved block of the invention does not require the use of mortar, it will be appreciated that the plastic resin for molding the block would have a zero absorption rate and can optionally be sealed with a silicone sealer during installation to render the cutting wall completely impenetrable by water. The plastic block of the invention includes a plurality of vertically oriented openings and a structure with thin walls to substantially decrease the weight, while not sacrificing strength. Further, the block is constructed to be easily reinforced with rebars and concrete. 
   Accordingly, it is an object of the present invention to provide a new and improved molded plastic block for use in erecting mortarless building walls with a building block system that reduces the time for erecting the walls and is capable of being used by unskilled laborers. 
   Another object of the present invention is to provide a self-aligning light-in-weight building block for erecting mortar-free walls of a building without the need to provide corner blocks or blocks of various incremental sizes to produce a building block system for making walls, thereby making it easy to handle by a worker erecting a wall. 
   A further object of this invention is to provide a building block of one size that can be easily and efficiently cut into three-quarter, half or quarter sizes for accommodating selected dimensional lengths of courses when building a wall. 
   Another object of the present invention is in the provision of an improved block for building mortarless building block walls wherein the block cost is minimized and wherein the labor time and skill involved is minimized. 
   A Further object is to provide a light-weight, easy-to-handle building block for making outer or inner walls of a building. 
   Other objects, features and advantages of the invention will be apparent from the following detailed disclosure, taken in conjunction with the accompanying sheets of drawings, wherein like reference numerals refer to like parts. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the improved block of the present invention looking at the top face of the block and the end having the receptor sockets or female Maltese sockets; 
       FIG. 2  is a perspective view of the improved block of the invention looking at the bottom of the block and the end of the block having the extrusions or male Maltese protrusions; 
       FIG. 3  is a perspective view of the block of the invention taken from the bottom of the block but looking at the opposite end of the block from the view of  FIG. 2  and where the receptors or Maltese sockets are located; 
       FIG. 4  is a top plan view of the building block of the invention and also showing the cutting planes for cutting the block into three-quarter, half and one-quarter lengths while maintaining the connections on the end faces; 
       FIG. 4A  is a top plan view of a quarter size block cut from a full size block; 
       FIG. 4B  is a top plan view of a half size block cut from a full size block; 
       FIG. 4C  is a top plan view of a three-quarter size block cut from a full size block; 
       FIG. 5  is a bottom plan view of the block of  FIG. 1 ; 
       FIG. 6  is a side elevational view of the block of  FIG. 1  showing one side and wherein the opposite side is identical as to the configurations of the vertically extending female Maltese sockets or receptors; 
       FIG. 7  is an end elevational view of the block of  FIG. 1  and looking at the end having the extrusions or male Maltese connectors; 
       FIG. 8  is an end elevational view of the opposite end of the block of  FIG. 1  and the end having the female Maltese sockets or receptors; 
       FIG. 9  is a transverse vertical sectional view taken along line  9 - 9  of  FIG. 4 ; 
       FIG. 10  is a transverse vertical sectional view taken along line  10 - 10  of  FIG. 4 ; 
       FIG. 11  is a vertical longitudinal sectional view taken along line  11 - 11  of  FIG. 4 ; 
       FIG. 12  is a vertical longitudinal sectional view taken along line  12 - 12  of  FIG. 4 ; 
       FIG. 13  is a perspective elevational view of a partial wall constructed by a plurality of blocks according to the invention showing a plurality of courses in stacked rows; 
       FIG. 14  is a perspective view of an inside corner of a wall constructed of the interlocking mortarless building blocks of the present invention forming a corner; 
       FIG. 15  is a perspective view of the outside corner of a wall shown in  FIG. 14 ; 
       FIG. 16  is a top plan view of a modified building block according to the invention showing the posts on the top face to be cylindrical rather than square; and 
       FIG. 17  is a top plan view of a further modified building block according to the present invention having arcuately formed extrusions and receptors on the opposite end faces and also showing cylindrical posts on the top face. 
   

   DESCRIPTION OF THE INVENTION 
   The present invention is unique in that it relates to an interlocking building block of the standard building block dimensions, being 12 inches long, 8 inches high and 6 inches wide. The block serves for a building block system to build walls that may be external or internal, such as for a residential home or an industrial building, and is capable of forming corners and openings for doors or windows without the need of providing corner blocks or blocks of other sizes. The block of the invention is of a single size which can easily be cut into three-quarter, half or quarter sizes at the construction site for configuring various wall construction requirements. The block is made of a suitable plastic resin such as urethane or a polypropylene and configured to be easily injection molded such that when it is removed from the mold it is in a finished form and not requiring any finishing operations before being shipped for use. Uniqueness of the design of the block enables it to be easily cut into three-quarter, half and one-quarter sizes while retaining the interlocking features needed to form an interlocking wall. The accurateness of an injection molded block further enables the close fitting together of interlocking blocks in courses and stacks to produce a wall that is substantially impenetrable to water or other liquids while maintaining a high insulating rating against thermoconductivity. 
   By virtue of providing only a single block configuration for a wall structure, substantial economies in manufacture of the block are accomplished. 
   Referring now to the drawings, and particularly to  FIGS. 1 to 3 , the building block of the present invention is generally designated by the numeral  20  and includes parallel opposed front and rear faces  22  and  24 , top and bottom parallel faces  26  and  28 , and opposed parallel end faces  30  and  32 . The opposed front and rear faces  22  and  24  are identical in that each includes vertically extending and equally spaced apart sockets or receptors  22   a ,  22   b ,  22   c  and  22   d  and  24   a ,  24   b ,  24   c  and  24   d . These sockets are tapered and in diverging relation from the bottom face  28  to the upper face  26 . The equally spaced apart relationship of these sockets will be further appreciated, as explained below, where the block may be separated or cut into three-quarter, half or quarter sections. 
   The opposed end faces  30  and  32  are configured for interlocking with adjacent blocks. The end face  30  is provided with a pair of spaced apart tapered sockets or receptors  30   a  and  30   b  which are identical to the receptors  22   a ,  22   b ,  22   c  and  22   d  and  24   a ,  24   b ,  24   c  and  24   d  on the opposed front and rear walls of the block. Likewise, the receptors  30   a  and  30   b  are tapered in a diverging fashion from the bottom face  28  to the upper face  26 . These receptors may also be considered to be female Maltese in cross section sockets or female dovetail sockets as would be the receptors in the opposed front and back faces of the block. 
   The opposed end face  32  of the block  20  is provided with extrusions or Maltese in cross section male connectors or male dovetail connectors/protrusions  32   a  and  32   b  sized to slide into and fit into under close tolerances with the receptors  30   a  and  30   b  of the face  30 , as well as the receptors  22   a ,  22   b ,  22   c  and  22   d  and  24   a ,  24   b ,  24   c  and  24   d  of the front and rear faces of the block. Depending upon the length of the block, whether it be three-quarter, half or quarter, and the need for a wall extending off a main wall of a structure, the extrusions  32   a  and  32   b  may fit into adjacent blocks rather than in a single block. 
   When placing the building blocks of the present invention to form a wall, the first course is suitably placed on a foundation where suitable guide elements are formed to cause adjacent blocks to be aligned with one another along a straight line. Upwardly jutting guide flanges may be formed in the foundation between which the blocks may be positioned, or any other suitable system may be used to provide suitable alignment of the first course blocks along a desired wall. 
   Thereafter, a second course of blocks is mounted on the first course such that each block in the second course will be staggered relative to the lower course as generally illustrated in  FIG. 13 . In order to preclude sliding movement between blocks in adjacent rows, posts are formed on the top face of each block which coact with receptors or sockets formed on the bottom faces of each block. As seen particularly in  FIGS. 1 and 2 , two rows of posts are formed on each block and designated  34   a ,  34   b ,  34   c  and  34   d  adjacent one vertical face of the block and  36   a ,  36   b ,  36   c  and  36   d  adjacent the opposing vertical face of the block. At the bottom face  28  of each block, two rows of receptors or sockets are provided coacting with the posts, wherein the row of receptors or sockets adjacent the front face of the block are designated  38   a ,  38   b ,  38   c  and  38   d , while the post receptors adjacent the rear face  24  of the block are designated  40   a ,  40   b ,  40   c  and  40   d . The post receptors or sockets  38  and  40  are equally spaced apart along the block as are the posts  34  and  36  such that upon placement of a block in an upper row onto blocks in the lower row, the front and back faces of all blocks will align with one another and be in the same plane. The posts  34  and  36  always face upwardly as they are on the top faces of the blocks, while the post sockets or receptors always face downwardly as they are on the bottom faces of the blocks. Moreover, as it will be appreciated that the blocks and adjacent rows are staggered relative to one another, the blocks in the next row up will be covering one-half of each of the blocks on the lower row. As above noted, all of the blocks in the present invention are identical in size, and they may be sectioned three-quarter, half or one-quarter in order to follow the dimensional layout of a wall as to openings for windows and doors. It should also be appreciated that the post receptors or sockets  38  and  40  are essentially three-quarter in size wherein receptors or sockets are open on the inside of the socket, as particularly noted in  FIG. 2 . This structure enhances the reduction of weight of the block while not impairing the block strength. It is also seen in  FIG. 2  that each of the receptors or sockets  38  and  40  includes a ledge or shoulder spaced inwardly from the outer ends of the sockets and generally against which the outer ends of the posts engage once an upper block is properly positioned on lower blocks. This enhances the stability and strength of a wall, although it should be appreciated that inasmuch as each upper block, when placed on lower blocks, engages such that the bottom face of the upper block rests on and fully engages the top face of a lower block. Sufficient tolerances are provided to prevent bottoming of the outer ends of the posts on the shoulders of the post sockets as to preclude any spacing between blocks in adjacent rows. 
   While the posts and post sockets are cross-sectionally square, it should be appreciated that they may take any suitable polygonal form and as below described with the embodiments of  FIGS. 16 and 17 , the posts and coacting post sockets may be circular or cylindrical in shape, or any other suitable arcuately formed shape. It will be appreciated that the posts and sockets of the particular building block according to the invention will be compatible with one another and such that they may matingly engage each other to provide the maximum strength values and also to facilitate the laying of the blocks in rows. 
   As seen particularly in  FIGS. 1 and 2 , the blocks are formed of integrating thin wall partitions in order to minimize the weight while not sacrificing the strength and requirement for such a building block. While the blocks may be made of any suitable plastic resin, such as urethane or polypropylene, it has been determined that a block made of a polypropylene homopolymer with carbon black as a UV inhibitor is preferred. More particularly, the material for the plastic resin in made of 70 percent calcium filled homopolymer polypropylene with 2 percent carbon black. The 2 percent carbon black serving as a UV inhibitor is adequate to prevent degradation of the plastic from the light prior to being closed in with a suitable outer layer or skin in a finished building structure. Moreover, a block of such a polypropylene will meet the tests established by ASTM of 1900 psi. The block of the invention, when compared to a concrete block, is substantially lighter in weight. A standard concrete building block weighs about 36 pounds, while a standard light-weight concrete block weighs 27 pounds. The block of the invention being only 4 pounds facilitates the handling of the block and the erection of a wall by unskilled laborers, as well as minimizing the cost of manufacture. 
   The block of the invention can also be further reinforced by the addition of rebars and by filling the blocks with concrete. In order to facilitate the use of rebars in a concrete filling operation, the block of the invention includes five transversely arranged partitions or panels  42   a ,  42   b ,  42   c ,  42   d  and  42   e . Each of the partitions includes at the upper and lower ends semi-circular cutouts  44  and  46 . Thus, the cutouts at the top face of the block are designated  44   a ,  44   b ,  44   c ,  44   d  and  44   e  as seen in  FIG. 1 , while the cutouts at the bottom face of each block are designated  46   a ,  46   b ,  46   c ,  46   d  and  46   e . The placement of one row of blocks onto the lower row of blocks therefore defines between those two rows by virtue of the semi-circular cutouts a circular opening extending all along the row of blocks. This circular opening serves to allow the introduction and placement of one or more rebars and concrete throughout the row of blocks wherein the concrete not only embeds the rebar but also fills the interior openings of each of the blocks, thereby greatly enhancing the strength and rigidity of a wall. However, it will be appreciated that it is not necessary to use rebars and concrete in each wall structure. This will depend upon the design requirements of a wall. 
   Also enhancing the light weight of the block of the invention is the inclusion of spaced apart vertically extending open channels  48  and  50 . Particularly as seen in  FIG. 1 , channels  48   a ,  48   b ,  48   c ,  48   d ,  48   e ,  48   f  and  48   g  are at the front face  22 , while channels  50   a ,  50   b ,  50   c ,  50   d ,  50   e ,  50   f  and  50   g  are at the rear face  24  of the block. Further, it will be appreciated that vertical channels are found between vertically extending partitions or panels  42   a ,  42   b ,  42   c ,  42   d  and  42   e . These vertically extending channels, while not numbered, are readily appreciated by viewing the perspective views of  FIGS. 1 and 2  and looking in the areas between the partitions. It will be appreciated that the partitions reinforce the overall structure of the block. 
   In addition to providing the Maltese-shaped or dovetail-shaped receptors  22   a ,  22   b ,  22   c  and  22   d  on the front face of the block and  24   a ,  24   b ,  24   c  and  24   d  on the rear face of the block, additional cutouts or recesses  52  and  54  are provided on the front and rear faces  22  and  24  respectively of each block. Except for the recesses at the very ends of the block, the recesses are in the shape of the head of an arrow by being wider at the lower end than at the upper end. This also facilitates the tapers needed for the injection molding of the blocks to permit the ease of removal of the block from a mold after it has been formed. 
   In order for the block of the invention to be sectioned at the job site to provide three-quarter, half and one-quarter lengths, the blocks are molded with two rows of vertically extending channels  56  and  58 . Channels  56   a ,  56   b  and  56   c  are provided adjacent the front face  22 , while channels  58   a ,  58   b  and  58   c  are provided adjacent the rear face of the block. These channels are in alignment from end to end of the block with the Maltese or dovetail receptors or sockets and Maltese or dovetail connectors on the opposite end faces of the block. The channels  56  align with the socket  30   b  on the end face  30 , and the connector  32   b  on the end face  32  of the block. Similarly, the channels  58  adjacent the rear face  24  of the block align with the receptor  30   a  and the connector  32   a  on the opposite end faces of the block. 
   Each of the channels  56  and  58  includes oppositely facing receptors capable of fitting with a connector from Maltese or dovetail-shaped male member. Thus, each channel includes oppositely facing Maltese shaped female members, as particularly illustrated in  FIG. 4 .  FIG. 4  is a top plan view of a block, and with reference to both  FIG. 4  as well as  FIGS. 4A ,  4 B and  4 C, it can be appreciated that the block of the invention can be sectioned into one-quarter, half or three-quarter lengths in order to satisfy dimensional requirements of a wall structure. As seen in  FIG. 4 , cutting planes  60   a ,  60   b  and  60   c  respectively allow cutting a block into a quarter length block section as seen in  FIG. 4A , a half length block section as seen in  FIG. 4B , and a three-quarter length block section as seen in  FIG. 4C . The symmetrical columns and formations of the block permit the sectioning of a block into the one-quarter, half and three-quarter lengths in order to accommodate dimensional requirements to form openings for windows and doors as required in a wall structure. 
   Although the block sections shown in  FIGS. 4A ,  4 B and  4 C each include male dovetail protrusions or connectors at one end of the block and female dovetail sockets at the other end of the block, it will be appreciated that in cutting a block along the cutting planes one of the two block sections will include only female dovetail sockets at both ends. These block sections can also be used where the end of the block to which a block section is to be connected includes male dovetail protrusions or connectors. Therefore, the ends of a block to which a block section is to be connected includes either male dovetail connectors or female dovetail sockets. The block section will be cut to provide the desired end face, and in some cases it will be desired that the end of the block not include male dovetail connectors. 
   Illustrative of the above explanation of block sections cutting the block of  FIG. 4  along the cutting plane  60   c  would produce a three-quarter size block having male dovetail connectors at one end and female dovetail sockets at the other end as well as a one-quarter block section having female dovetail sockets at both ends. Cutting the block shown in  FIG. 4  along the cutting plane  60   b  would produce a half block having male dovetail connectors at one end and female dovetail sockets at the other end together with a half block having female dovetail sockets at both ends. Cutting the block in  FIG. 4  along cutting plane  60   a  would produce a quarter block having male dovetail connectors at one end and female dovetail sockets at the other end together with a three-quarter size block having female dovetail sockets at both ends. 
   Referring now to  FIGS. 13 ,  14  and  15 , the construction of a wall with blocks according to the present invention is illustrated. As seen in  FIG. 13 , a wall is constructed with blocks of the present invention with a first course  62  suitably placed on a foundation that is not shown. After the first course has been completed, that includes a plurality of blocks in end-to-end relation, the second course  64  is stacked onto the first course with the blocks in the second course staggered such that each block in the second course that is fully engaged by blocks of the first course would place each block in overlapping relation with two blocks in the first course. In view of the symmetrical shape and placement of components of each block, the first block laid in the second course  64 , while preferably overlapping to blocks equally in the first course, could be otherwise placed to overlie three quarters of a block in the first course of one block and only one quarter of an adjacent block. When assembling the first course, it will be appreciated that the male dovetail connectors will be aligned with and inserted into the female dovetail sockets of adjacent blocks to interconnect them together in a close-fitting relationship. Application of the blocks in the second course will include aligning the post receptors of the blocks in the second course with the posts of the blocks in the first course. This process is continued with courses  66 ,  68  and  70  until the desired height of the wall is reached. Where there would be a desire to have vertically aligned faces of the blocks, block sections would be used to accomplish that end goal. 
     FIGS. 14 and 15  are illustrations of the inner side of a corner and the outer side of a corner where it is desired to have a corner and blocks to define a wall that is perpendicular to the first wall. In this arrangement, the blocks with male connector ends are interconnected with female dovetail sockets at one side of a block to interconnect the wall at the corner to the main wall of the blocks. In  FIG. 14 , three courses of stacked blocks are shown on the main wall and designated  72 ,  74  and  76 , while only two courses  78  and  80  are shown on the wall that connects to the main wall for purposes of defining a corner. When making a corner and for the purpose of extending a wall perpendicular to the main wall, it will be appreciated that the wall turning the corner will have the lower course connected prior to beginning the second course  74 . Similarly, the course  80  would be in place before beginning the course  76 . 
   The corner wall structure shown in  FIG. 15  differs from the wall structure of  FIG. 14  in that it shows the outside of the corner and includes one more course of blocks. The main course at the lower end is designated  82  and the side course  84  would be attached to the main course  82  prior to laying the next row of blocks. A second course on the main wall is designated  86 , and its side course forming the wall perpendicular to the main wall is designated  88 . The course of blocks above the courses  86  and  88  includes the course  90  stacked on the course  86 , and the turning course  92  stacked on the course  88 . The last course  94  is shown overlapping the side course  92  as well as extending across and on top of the course  90 . There will be an alternating placement of blocks such that the end block in the course  84  connects to the male dovetail connectors of the next block in the course  82 , while the end block of the course  86  overlaps the last block in the course  84 . While the construction of the wall in this embodiment will give the best strength value, it can be appreciated that it can otherwise be set up in view of the symmetrical formation of each block with its posts and post receptors. 
   Referring now to the embodiment of  FIG. 16 , this block  20   a  differs from the embodiment of  FIG. 1  in that the posts employed on the top face of the block are circular or round rather than being square in shape. Otherwise, this embodiment is the same as the embodiment of  FIG. 1 . The posts are designated in one row as  96   a ,  96   b ,  96   c  and  96   d , while the posts in the other row are designated  98   a ,  98   b ,  98   c  and  98   d . Further, the sockets or receptors for receiving the posts will be circular or cylindrical in shape so that there is a close mating relationship between the posts and the sockets between adjacent rows or courses of building blocks. This embodiment also includes the same male dovetail protrusion or connector as well as female dovetail sockets shown in the embodiment of  FIGS. 1 to 12 . 
   The block  20   b  of  FIG. 17  differs from the embodiment of  FIG. 16  only in the cross-sectional shape of the connectors at one end of the block and the sockets in the other end of the block. The connectors of this block designated as  100  and  102  are parti-cylindrical in cross section and tapered between ends, thereby providing arcuate faces for engagement with sockets so they would closely receive the connectors. The sockets are designated  104  and  106  and sized to mate with the connectors, and include parti-circular form to coact with the connectors like  100  and  102 . Similarly, the sockets provided on the front and back sides of the block would be of the same shape as those at the end face of the block so that they would be compatible with the connectors  100  and  102 . Finally, it will be appreciated that the vertical channels designated as  108   a ,  108   b  and  108   c  on one side of the block and  110   a ,  110   b  and  110   c  on the other side of the block are formed such that when cutting the block into shorter block sections they will provide sockets like the sockets  104  and  106  for mating with the connectors  100  and  102 . It will be appreciated that other forms of connectors and sockets may be employed so long as the proper connecting relationship can be obtained between adjacent blocks as well as when forming a corner or forming a wall that extends from the middle of another wall as a suitable partition in a building. 
   It should also be appreciated that once a wall or walls of the building blocks according to the present invention have been erected, they may be covered with a suitable outer sheathing or a brick veneer wall. Where bricks are used, tie-ins can easily be connected between the mortar joints of a brick veneer wall and any of the female sockets along the side of the wall, or the inverted V-shaped recesses. 
   It will be understood that modifications and variations may be effected without departing from the scope of the novel concepts of the present invention, but it is understood that this application is to be limited only by the scope of the appended claims.