Construction Block

• US 20080155929A1
• Filed: 11/27/2007
• Published: 07/03/2008
• Est. Priority Date: 12/15/2006
• Status: Active Grant

• Current Assignee: Global Shelter Systems, Inc. (HESCO Blastbloc Ltd.)
• Original Assignee: Global Shelter Systems, Inc. (HESCO Blastbloc Ltd.)
• Inventors: Herron, Burke A.
• Granted Patent: US 7,765,744 B2
• Time in Patent Office: Days
• US Class Current: 52/582.1
• CPC Class Codes: E04B 2/84 Walls made by casting, pouring, or tamping in situ E04B2/02, E04B2/56 take precedence; forms therefor E04G11/06; working of concrete or similar masses able to be cast or poured in situ E04G21/02
• CPC Class Codes: E04C 1/395 for claustra, fences, planting walls, e.g. sound-absorbing pots for vertical horticulture A01G9/022
• CPC Class Codes: E04H 9/04 against air-raid or other war-like actions
• CPC Class Codes: F41H 11/08 Barbed-wire obstacles; Barricades; Stanchions; Tank traps; Vehicle-impeding devices; Caltrops making barbed wire B21F25/00; barbed-wire fencing E04H17/04; road barricades, obstructing passage of vehicles or pedestrians E01F13/00
• CPC Class Codes: F42D 5/045 Detonation-wave absorbing or damping means

Abstract

A construction block is provided that includes at least one base member that includes a plurality of lower side wall receptacles. The construction block further includes a plurality of side wall assemblies. Each of the side wall assemblies includes a plurality of interconnected panels. Each of the panels is hingedly connected to each adjacent one of the panels of the respective one of the side wall assemblies. Each of the side wall assemblies defines a hollow load chamber having an open top and an open bottom. At least some of the panels of each of the side wall assemblies are angled relative to one another. Each of the lower side wall receptacles receives one of the side wall assemblies.

Claims

1. A collapsible side wall assembly for use in a construction block, said collapsible side wall assembly comprising:

a plurality of interconnected panels, each of said panels being disposed intermediate a pair of said panels and hingedly connected to each one of said pair of said panels, said plurality of interconnected panels being movable between a collapsed configuration and an erected configuration;

wherein

said plurality of interconnected panels define a hollow load chamber having an open top and an open bottom when said plurality of interconnected panels are in said erected configuration;

each of said panels comprises a central portion having an inner surface and a generally planar outer surface and further comprises first and second sides and first and second end flanges, said central portion extending between said first and second sides and between said first and second end flanges, said generally planar outer surfaces of said central portions of at least some of said panels being angled relative to one another when said plurality of interconnected panels are in said erected configuration;

said first end flange and said second end flange are offset inwardly from said generally planar outer surface of said central portion, for at least some of said panels.

2. The collapsible side wall assembly of claim 1, wherein, when viewed in transverse cross-section and when said plurality of interconnected panels are in said erected configuration:

said generally planar outer surfaces of said central portions of said panels cooperate to define a polygon.

3. The collapsible side wall assembly of claim 2, wherein:

said polygon is an octagon.

4. The collapsible side wall assembly of claim 1, further comprising:

a plurality of male hinge members;

wherein

each of said panels further comprises a first plurality of female hinge members extending away from said first side and a second plurality of female hinge members extending away from said second side, said first plurality of female hinge members being misaligned with said second plurality of female hinge members; and

each of said male hinge members extends through said first plurality of female hinge members of one of said panels and through said second plurality of female hinge members of an adjacent one of said panels.

5. The collapsible side wall assembly of claim 1, wherein:

each of said panels comprises a thermoplastic material.

6. A collapsible side wall assembly for use in a construction block, said collapsible side wall assembly comprising:

a plurality of interconnected panels, each of said panels being disposed intermediate a pair of said panels and hingedly connected to each one of said pair of said panels, each of said panels comprising a central portion having an inner surface and an outer surface, each of said panels comprising a thermoplastic material, said plurality of interconnected panels being movable between a collapsed configuration and an erected configuration;

wherein

said plurality of interconnected panels define a hollow load chamber having an open top and an open bottom when said plurality of interconnected panels are in said erected configuration, said outer surfaces of said central portions of at least some of said panels being angled relative to one another when said plurality of interconnected panels are in said erected configuration.

7. The collapsible side wall assembly of claim 6, wherein:

said thermoplastic material comprises a polymer.

8. The collapsible side wall assembly of claim 7, wherein:

said polymer comprises a high impact plastic.

9. The collapsible side wall assembly of claim 6, wherein:

each of said panels comprises first and second sides, said central portion extending continuously between said first and second sides.

10. The collapsible side wall assembly of claim 9, wherein:

at least one of said panels further comprises a coating applied to said outer surface of said central portion.

11. The collapsible side wall assembly of claim 6, wherein:

at least one of said panels further comprises a reinforcing member.

12. The collapsible side wall assembly of claim 11, wherein:

said reinforcing member is made of a material selected from the group consisting of a metal, a metal alloy, a ceramic, a polymer and a fabric.

13. A construction block comprising:

at least one base member comprising a plurality of lower side wall receptacles;

a plurality of side wall assemblies, each of said side wall assemblies comprising a plurality of interconnected panels, each of said panels being hingedly connected to each adjacent one of said panels of a respective one of said side wall assemblies, each of said side wall assemblies defining a hollow load chamber having an open top and an open bottom, at least some of said panels of each of said side wall assemblies being angled relative to one another;

at least one lid comprising a plurality of upper side wall receptacles;

wherein

each of said lower side wall receptacles receives a respective one of said side wall assemblies; and

each of said upper side wall receptacles receives a respective one of said side wall assemblies.

14. The construction block of claim 13, wherein:

said at least one base member further comprises upper and lower surfaces and a lower boundary flange, said upper surface and said lower boundary flange cooperating to define said lower side wall receptacles;

said at least one lid further comprises upper and lower surfaces and an upper boundary flange, said lower surface and said upper boundary flange cooperating to define said upper side wall receptacles;

at least one of said panels of each of said side wall assemblies releasably engages said lower boundary flange; and

at least one of said panels of each of said side wall assemblies releasably engages said upper boundary flange.

15. The construction block of claim 13, wherein:

said at least one base member comprises a single base member, said base member comprising a pair of said lower side wall receptacles;

said plurality of side wall assemblies comprises a first side wall assembly and a second side wall assembly connected to said first side wall assembly;

said at least one lid comprises a single lid, said lid comprising a pair of said upper side wall receptacles;

said base member further comprises a lateral centerline axis, said pair of said lower side wall receptacles being generally symmetrically disposed about said lateral centerline axis of said base member; and

said lid further comprises a lateral centerline axis, said pair of said upper side wall receptacles being generally symmetrically disposed about said lateral centerline axis of said lid.

16. The construction block of claim 13, wherein:

each of said panels of each of said side wall assemblies comprises a thermoplastic material.

17. The construction block of claim 16, wherein:

said thermoplastic material comprises a polymer.

18. The construction block of claim 17, wherein:

said polymer comprises a high impact plastic.

19. The construction block of claim 13, wherein:

each of said panels of each of said side wall assemblies comprises first and second sides and a central portion extending between said first and second sides, said central portion having an inner surface and a generally planar outer surface; and

when viewed in transverse cross-section, said generally planar outer surfaces of said central portions of said panels cooperate to define a polygon, for each of said side wall assemblies.

20. The construction block of claim 19, wherein:

said polygon is an octagon.

21. The construction block of claim 19, wherein:

each of said panels of each of said side wall assemblies further comprises a first end flange and a second end flange; and

said central portion extends between said first end flange and said second end flange, said first end flange and said second end flange being offset inwardly from said generally planar outer surface of said central portion, for each of said panels of each of said side wall assemblies.

22. The construction block of claim 14, wherein:

said lower surface of said at least one base member comprises a plurality of recessed ledges, each of said recessed ledges having a first shape; and

said at least one lid further comprises a plurality of protrusions extending upwardly from said upper surface of said lid, each of said protrusions having a second shape that is complementary to said first shape of said recessed ledges of said at least one base member.

23. The construction block of claim 13, wherein:

said at least one base member further comprises a plurality of apertures, each of said apertures being in one of said lower side wall receptacles, each of said apertures communicating with said load chamber of a respective one of said side wall assemblies.

24. A structure made from a kit of construction block components, said kit comprising:

a plurality of base members,

a plurality of collapsible side wall assemblies;

wherein

each of said side wall assemblies comprises a plurality of hingedly interconnected panels, each of said sidewall assemblies being movable between a collapsed configuration and an erected configuration, wherein said side wall assemblies define, in said erected configuration, a hollow load chamber having an open top and an open bottom;

said structure comprises a base layer comprising a first plurality of said base members disposed adjacent one another;

said base layer of said structure further comprises a first plurality of said collapsible side wall assemblies, in said erected configuration; and

each of said base members of said base layer releasably engages at least one of said erected side wall assemblies.

25. The structure of claim 24, wherein:

said kit further comprises a plurality of lids;

said base layer of said structure further comprises a first plurality of said lids;

each of said first plurality of said erected side wall assemblies of said base layer releasably engages one of said first plurality of said lids.

26. The structure of claim 25, wherein:

each of said panels of each of said side wall assemblies of said kit comprises first and second sides and a central portion extending between said first and second sides, said central portion having an inner surface and a generally planar outer surface, said generally planar outer surfaces of at least some of said panels of each of said side wall assemblies, when in said erected configuration, being angled relative to one another.

27. The structure of claim 26, wherein for each respective one of said side wall assemblies, when viewed in transverse cross-section and when said side wall assembly is in said erected configuration:

said generally planar outer surfaces of said central portions of said panels cooperate to define a polygon.

28. The structure of claim 27, wherein:

said polygon is an octagon.

29. The structure of claim 27, wherein:

each of said panels of each of said side wall assemblies comprises a thermoplastic material.

30. The structure of claim 25, wherein:

said base layer of said structure further comprises a first plurality of sets of said erected side wall assemblies, each of said first plurality of sets of said erected side wall assemblies comprising at least two connected ones of said erected side wall assemblies, each of said first plurality of sets of said side wall assemblies interconnecting an adjacent pair of said base members of said base layer;

said structure further comprises a second layer comprising a second plurality of said base members; and

each of said second plurality of said base members of said second layer is releasably engaged with at least one of said lids of said first plurality of said lids of said base layer.

31. The structure of claim 30, wherein:

each of said second plurality of said base members of said second layer is releasably engaged with each one of an adjacent pair of said lids of said first plurality of said lids of said base layer; and

said second layer further comprises a second plurality of sets of said erected side wall assemblies, each of said sets of said second plurality of said erected side wall assemblies comprising at least two connected ones of said erected side wall assemblies;

each of said second plurality of said sets of said erected side wall assemblies of said second layer releasably engages each one of an adjacent pair of said second plurality of said base members of said second layer; and

each of said load chambers of said second layer communicates with one of said load chambers of said base layer.

32. The structure of claim 31, further comprising:

ballast material filling at least some of said load chambers of said base layer and at least partially filling at least some of said load chambers of said second layer.

33. The structure of claim 30, wherein:

each of said base members of said kit comprises upper and lower surfaces, said lower surface defining a plurality of recessed ledges having a first shape; and

each of said lids of said kit comprises upper and lower surfaces and a plurality of protrusions extending upwardly from said upper surface, said protrusions having a second shape that is complementary with said first shape of said recessed ledges of said base members of said kit.

34. The structure of claim 25, wherein:

said structure further comprises a second layer comprising a second plurality of said base members; and

each of said second plurality of said base members of said second layer is releasably engaged with each one of an adjacent pair of said lids of said first plurality of said lids of said base layer.

35. The structure of claim 25, wherein:

each of said base members of said kit, each of said panels of each of said side wall assemblies of said kit and each of said lids of said kit comprise a thermoplastic material.

36. The structure of claim 24, wherein:

said kit further comprises a first plurality of hybrid members;

said base layer further comprises a first plurality of said hybrid members; and

each of said first plurality of said erected side wall assemblies of said base layer releasably engages one of said first plurality of said hybrid members.

37. The structure of claim 36, wherein:

said structure further comprises a second layer comprising a second plurality of said erected side wall assemblies, each one of said second plurality of said erected side wall assemblies of said second layer being releasably engaged with one of said hybrid members of said base layer.

38. A structure comprising:

a base layer comprising a first plurality of construction blocks positioned adjacent one another;

a second layer comprising a second plurality of said construction blocks positioned adjacent one another, each of said second plurality of said construction blocks being positioned on top of and releasably engaged with at least one of said construction blocks of said first plurality of said construction blocks;

wherein

each of said construction blocks of said first and second pluralities of said construction blocks comprises a lid, a base member and a plurality of side wall assemblies, each of said side wall assemblies being releasably engaged with said lid and said base member;

each of said side wall assemblies of said first and second pluralities of said construction blocks comprise a plurality of hingedly interconnected panels, each of said panels being hingedly connected to each adjacent one of said panels of a respective one of said side wall assemblies of said first and second pluralities of said construction blocks, each of said side wall assemblies of said first and second pluralities of said construction blocks defining a hollow load chamber having an open top and an open bottom, at least some of said panels of each of said side wall assemblies of said first and second pluralities of said construction blocks being angled relative to one another; and

at least one of said panels of each of said side wall assemblies of said first and second pluralities of said construction blocks comprises a thermoplastic material.

39. The structure of claim 38, wherein:

each of said second plurality of said construction blocks of said second layer releasably engages an adjacent pair of said first plurality of said construction blocks of said first layer.

40. A method of building a modular structure, the method comprising:

providing a kit of construction block components comprising a plurality of base members, and a plurality of collapsible side wall assemblies, each of the collapsible side wall assemblies comprising a plurality of hingedly interconnected panels, each of the side wall assemblies being movable between a collapsed configuration and an erected configuration, wherein each of the side wall assemblies define, in the erected configuration, a hollow load chamber having an open top and an open bottom;

building a base layer of the structure, wherein the step of building the base layer comprises;

arranging a plurality of the base members of the kit adjacent to one another on a support surface;

releasably engaging each of the base members of the base layer with at least one of the side wall assemblies of the kit, in the erected configuration.

41. The method of claim 40, wherein:

providing the kit further comprises providing a plurality of lids; and

building the base layer of the structure further comprises releasably engaging each one of the erected side wall assemblies of the first layer with one of the lids of the kit.

42. The method of claim 40, wherein:

providing the kit further comprises providing a plurality of sets of the side wall assemblies, with each set comprising at least two of the side wall assemblies connected to one another; and

building the base layer further comprises releasably engaging one of the sets of the side wall assemblies, with each of the side wall assemblies of the set being in the erected configuration, with an adjacent pair of the base members of the base layer.

43. The method of claim 41, further comprising:

building a second layer of the structure positioned on top of, and engaged with, the first layer of the structure, wherein building the second layer comprises;

releasably engaging one of the base members of the kit with at least one of the lids of the first layer of the structure.

44. The method of claim 43, wherein building the second layer further comprises:

releasably engaging each one of the base members of the second layer with at least one of the side wall assemblies of the kit, in the erected configuration.

45. The method of claim 44, further comprising:

configuring the lids of the base layer of the structure and the base members of the second layer so that each load chamber of the second layer communicates with one of the load chambers of the base layer;

wherein

at least partially filling the load chambers of the base layer comprises completely filling the load chambers of the base layer with ballast material; and

the method further comprises at least partially filling the load chambers of the second layer with ballast material.

46. The method of claim 44, wherein:

each of the side wall assemblies of the second layer is connected to at least one other side wall assembly of the second layer.

47. The method of claim 40, wherein:

each of the base members of the kit, each of the side wall assemblies of the kit and each of the lids of the kit are made of a thermoplastic material.

48. A method of manufacturing a kit of construction block components, the method comprising:

forming a plurality of panels from a thermoplastic material, the panels being configured to create at least one side wall assembly;

forming a base member from a thermoplastic material, the base member being configured to releasably engage the at least one side wall assembly; and

forming a lid from a thermoplastic material, the lid being configured to releasably engage the at least one side wall assembly.

49. The method of claim 48, wherein forming a plurality of panels comprises:

separately molding each one of the panels from a thermoplastic material;

wherein said method further comprises hingedly connecting each panel to two adjacent panels to form a side wall assembly, wherein the side wall assembly is movable between a collapsed configuration and an erected configuration in which the side wall assembly defines a hollow load chamber having an open top and an open bottom.

50. The method of claim 49, wherein:

forming the base member comprises molding the base member from a thermoplastic material and configuring the base member to include upper and lower surfaces and a lower boundary flange, with the lower boundary flange and the upper surface cooperating to define at least one lower side wall receptacle, the at least one lower side wall receptacle being configured to receive the side wall assembly in the erected configuration; and

forming the lid comprises molding the lid from a thermoplastic material and configuring the lid to include upper and lower surfaces and an upper boundary flange, with the lower surface and the upper boundary flange cooperating to define at least one upper side wall receptacle, the at least one upper side wall receptacle being configured to receive the side wall assembly in the erected configuration.

51. The method of claim 50, wherein:

forming the base member further comprises forming at least one recessed ledge in the at least one lower side wall receptacle, the ledge having a first shape; and

forming the lid further comprises configuring the lid to include at least one protrusion extending upwardly from the upper surface of the lid, the protrusion having a second shape that is complementary with the first shape of the recessed ledge of the base member.

52. The method of claim 48, further comprising:

coating an outer surface of at least one of the panels.

53. The method of claim 48, wherein said method further comprises:

strengthening at least one of the panels with at least one reinforcement member.

54. The method of claim 53, wherein:

the reinforcement member is made of a material selected from the group consisting of a metal, a metal alloy, a ceramic, a polymer and a fabric.

55. The method of claim 48, wherein:

forming the plurality of panels comprises molding the panels from the thermoplastic material to form a strip of the panels with each adjacent pair of the panels connected by a living hinge; and

the method further comprises folding the strip of panels to create two of the side wall assemblies, each defining a hollow load chamber.