INTERLOCKING ASYMMETRIC UNIVERSAL CONSTRUCTION BLOCK
An asymmetrical interlocking universal construction element with a unique polygonal shape. It allows for constructing flat surfaces, internal corner, and external corner surfaces from a set consisting essentially of the same construction elements. It can be used to finish edges of an opening in a flat surface (e.g., for a door or window). Construction elements can be cut to size on-site. Assembly of two or more construction elements allows insertion of an S-shaped thin-walled metal element to provide load bearing capability. Application of the elements in construction assembly may use any raw material as long as it is shape-stable (i.e., capable of carrying its own weight only). The construction elements may be hollow or solid throughout.
The use of interlocking construction blocks dates back to Greek and Roman times, and perhaps earlier. Keystones often held brick structures together. U.S. patent history of interlocking construction blocks dates back to the beginning of the twentieth century. The earlier blocks had simple interlocking construction. In 1916, J. J. Funsten invented a system of complex shape construction blocks with interlocking grooves (U.S. Pat. No. 1,167,746). A plurality of these blocks could mate together to produce strong integral structures. Funsten's blocks had planar external faces with S-shaped internal surfaces. In 1920, I Pomerantz invented interlocking construction blocks that were hollow (U.S. Pat. No. 1,332,409). This was followed by Baumann (U.S. Pat. No. 1,356,590), who invented a complex system of somewhat hollow construction blocks. Baumann's invented three different complex hollow symmetrical blocks interlocking blocks. Baumann needed the three blocks to create walls with corners. Most of this inventive activity in the United States took place prior to 1942. It picked up again during the 1960's, and continued to a much lesser extent until the present. In 1965, Nofziger invented two interlocking blocks that would mate together to form a post (U.S. Pat. No. 3,170,201). In 2003, Boot invented a complex system of interlocking concrete blocks to be used in construction (U.S. Pat. No. 6,508,041). Except for Nofziger, the inventors were mainly concerned with wall construction.
Generally, prior art construction block systems require different shaped blocks to be able to create a structure. The designs of most systems use symmetrical blocks, even though asymmetry is an advantage. A universal interlocking block is not available. The advantage of a universal block is to create floors, walls, and posts, which are the products of construction. Furthermore, the activity of inventors in this field has been limited to certain standard construction materials (e.g., brick, concrete, and wood). Construction elements fabricated from sheet metal do not exist. Interlocking insulation blocks are not available.
SUMMARY OF THE INVENTIONThe Present Invention is an asymmetrical interlocking universal construction element with a unique polygonal shape. It allows for constructing flat surfaces, internal corner, and external corner surfaces from a set consisting essentially of the same construction elements. It can be used to finish edges of an opening in a flat surface (e.g., for a door or window). Construction elements can be cut to size on-site. The shape of the construction element enables production by cutting (extruding) with less than three-percent loss. The shape of the construction element enables production by cutting (extruding) units out of a slab of raw material with zero-loss. Assembly of two or more construction elements allows insertion of an S-shaped thin-walled metal element to provide load bearing capability. Application of the elements in construction assembly may use any raw material as long as it is shape-stable (i.e., capable of carrying its own weight only). The construction elements may be hollow or solid throughout.
The construction element of the Present Invention may be completely solid, partially hollow, or completely hollow.
Construction elements of the Present Invention may be load bearing, but they do not need to be load bearing. They can be fabricated as bricks, plaster, or wood logs. They may be made of plastic, which can be translucent or transparent. They may even be fabricated from insulating material. Insulating construction blocks may be cut on-site using a hot wire. Plastic or metal construction elements can be fabricated by extrusion or by pouring into a form. The construction elements may be made from any material that is shape-stable by itself or made shape-stable with glues or additives. They can be produced in any desired length along the longitudinal axis, and may be of any desired thickness. For example, the polygonal construction elements may be fabricated as patio bricks which would then be assembled to form a flat surface stone floor. The construction elements in vertical beams assembled from multiple elements may have construction elements made of different materials. For example, some of the elements could be made from structurally sound material, while others could be fabricated from insulating material. The construction elements may be assembled to form a wall whose interior surface is a smooth wall. On the other hand, sheet rock can be fastened to interior surfaces. Studs are not required for production of a wall. Plywood or other wood can be fastened to floor assemblies.
The asymmetric shape of the construction element is unlike any found in the prior art. The shape of the element allows for constructing a flat surface along with external and internal corner surfaces with a single type of construction element. Finishing edges of an opening in a flat surface (e.g., for a door or window) may be produced on-site by making a single horizontal cut of the construction assembly. U-shaped or S-shaped components may be added to the construction element assembly. The construction element design allows for mistake-proof assembly by low-skilled workers. The construction elements may be mass produced. A completely hollow construction element may be fabricated by folding sheet metal. Some elements from folded web material can be produced from a material having shape memory. Thus, all of the construction elements may be shipped flat to their destination, and then would be either folded or unfolded on-site.
As previously discussed, the vertices of the nineteen-sided polygon that forms the ends of the construction element may be curved as long as the sides of the polygon are essentially straight lines that are perpendicular to each other.
GLOSSARYIn drafting this patent application, the Inventor has chosen to be his own lexicographer. The definitions of terms presented herein supersede the plain and ordinary meaning of these terms.
1. U-Shape—A shape consisting of three essentially linear elements, wherein two of said elements are parallel to each other and each perpendicular to the third element.
2. S-Shape—A shape consisting of five essentially linear elements, wherein each of the first set of three elements are parallel to each other; wherein each of the second set of two of elements are parallel to each other; and wherein each of the first set of three elements is perpendicular to an element of the second set of two elements. The shape is shown in
3. Web Material (or Web or Webbing)—A thin sheet of essentially planar material that can be cut or bent into a desired shape.
Claims
1. A three-dimensional construction element comprising:
- a) a length along a longitudinal axis;
- b) two essentially planar end surfaces having edges forming a perimeter comprising a closed irregular polygon with at least one end surface being perpendicular to the longitudinal axis, and wherein the end surfaces are separated from each other by the length of the construction element;
- c) wherein a cross-section of the construction element anywhere along its length and perpendicular to its longitudinal axis is a plane having edges that define a closed irregular polygon congruent to and parallel to the at least one end surface that is perpendicular to the longitudinal axis;
- d) wherein the irregular polygon formed by the edges of the at least one end surface that is perpendicular to the longitudinal axis and cross-section perpendicular to the longitudinal axis consists of nineteen sides, nineteen vertices, and nineteen internal angles all of which are essentially ninety degrees; and
- e) wherein any cross-section that is perpendicular to the longitudinal axis forms an irregular polygon that is congruent to and parallel to the at least one end surface that is perpendicular to the longitudinal axis.
2. The construction element of claim 1, wherein each of the two end surfaces are congruent to the other and parallel to the other, and wherein both end surfaces are perpendicular to the longitudinal axis.
3. The construction element of claim 1, wherein said construction element is produced using an extrusion process.
4. The construction element of claim 1, wherein said construction element is solid throughout.
5. The construction element of claim 1, wherein said construction element is hollow with a solid exterior having thickness.
6. The construction element of claim 5, wherein the thickness of the solid exterior is small compared to a linear dimension of any edge of the irregular polygon.
7. The construction element of claim 6, wherein the solid exterior is constructed from a web material.
8. The construction element of claim 7, wherein the web material is a plastic sheet.
9. The construction element of claim 7, wherein the web material is a metal sheet.
10. The construction element of claim 7, wherein the solid exterior is produced by folding the web material into the shape of the irregular polygon.
11. The construction element of claim 10, wherein the shape of the solid exterior is secured so that it cannot unfold.
12. A beam, block, or post having a rectangular cross-section throughout that is produced by interlocking four of the construction elements of claim 1.
13. A linear construction element formed by interlocking a plurality of the construction elements of claim 1 in a linear direction.
14. A corner element comprising an external planar surface, an internal planar surface, an exterior corner angle being 90 degrees, and an internal corner angle being ninety degrees, wherein the corner construction element is produced by interlocking two linear construction elements of claim 13.
15. The construction element of claim 1, wherein said construction element is cut along a planar axis parallel to the longitudinal axis and along the entire length, so as to produce a first smaller construction element and a second smaller construction element, such that both the first and second smaller construction elements can be oriented and interlocked to form a single rectangular beam, block, or post.
16. A linear construction element comprising two end pieces, wherein said linear construction element is formed by interlocking a plurality of construction elements in a linear direction, wherein one end piece is the first smaller construction element of claim 15 and the second end piece is the second smaller construction element of claim 15.
17. A corner element comprising an external planar surface, an internal planar surface, an exterior corner angle being 90 degrees, and an internal corner angle being ninety degrees, wherein the corner construction element is produced by interlocking construction elements with either the first or second smaller construction element of claim 15.
18. An assembly of interlocking construction elements of claim 1, wherein at least one S-shaped sheet elements having squared edges is integrated into the interlocked edges.
19. The assembly of claim 18, wherein the at least one S-shaped sheet element provides vertical load bearing capability to the assembly.
20. An assembly of interlocking construction elements of claim 1 that rest upon a U-shaped bottom sheet tray having squared edges.
21. An assembly of interlocking construction elements of claim 1, upon the top of which rests a cover comprising a U-shaped sheet element having squared edges.
22. The construction element of claim 1 wherein the at least one vertex of the nineteen vertices are curved.
Type: Application
Filed: May 31, 2015
Publication Date: Oct 22, 2015
Inventor: Sergei Kobelev (Manalapan, NJ)
Application Number: 14/726,554