Interlocking blocks and tiles for buildings

Abstract

A set of prefabricated, interlocking plastics components for construction of a building of any shape is described. The components are preferably rotationally moulded or extruded as regular shapes (rectangles, triangles or hexagons) from thermoplastics materials. Moulding allows each component to be comprised of more than one region or layer of material, or to include a void. The building can be carried to a site as individual or aggregated components as dictated by the transport facilities available, then erected at the site. Disassembly is facilitated if non-adhesive fasteners are used to secure the tongue and groove joints.

I claim: 
     
         1 . Interlockable components comprising a mutually interlockable set for use in building construction characterised in that each component of the set has an exterior comprised of a fused thermoplastics material and an interior; each component conforming to standardised dimensions at least with respect to a complementary interlocking portion, the set of components including:
 a) rectangular wall panels; the panels being interlockable in two perpendicular axes;   b) rectangular outer wall panels having a domed external surface; the panels being interlockable in two perpendicular axes;   c) rectangular outer wall panels having an environmentally resistant external surface;   the panels being interlockable in two perpendicular axes.   
     
     
         2 . An interlockable component for use as part of a set as claimed in  claim 1 , characterised in that tongue and groove complementary joints having standardised, compatible dimensions are provided along mating edges of the component, said joints comprising the interlocking portions; said joints being capable of being joined together by adhesive or physical fastening means. 
     
     
         3 . A further range of components compatible with the interlockable component claimed in  claim 2 ; characterised in that the components are selected from a range including: interlockable corner pillars; interlockable rectangular full-height wall panels; interlockable elongated roof tile panels; window frames; door frames; panels having an integrated window within an aperture; panels having a gap into which a window frame may be inserted; and panels which when interlocked form a gap into which a window may be inserted; 
     
     
         4 . An interlockable component as claimed in  claim 2 ; characterised in that the component is comprised of fused together thermoplastics granules having at least a first composition; the component having been melted together within a heated mould. 
     
     
         5 . An interlockable component as claimed in  claim 4 ; characterised in that an external layer of the component is entirely comprised of a fused mass formed by heating and melting a first selected composition including a first type of non-foaming type of thermoplastics granule within a heated mould during rotation of the mould; the external layer surrounding a void. 
     
     
         6 . An interlockable component as claimed in  claim 4 ; characterised in that a portion of the external layer of the component is comprised of a fused mass formed by heating and melting a second selected composition including a non-foaming type of thermoplastics granule within a heated mould while not fully rotating the mould; the external layer surrounding a void. 
     
     
         7 . An interlockable component as claimed in  claim 5 ;
 characterised in that the void within the component is filled with a fused, foamed mass formed by subsequent introduction of a foaming type of thermoplastics granule into the heated mould so that, after moulding, the foamed mass is contained within a non-foamed external mass, together comprising the interlockable component.   
     
     
         8 . A method for manufacturing interlockable building components; the method including the steps of:
 a) creating an openable and releasable mould for each distinct shape of component, b) heating an oven to a working temperature,   c) loading each mould with an amount of a thermoplastics material preferably as granules,   d) placing each mould in the oven while rotating the mould so that all parts of the mould are internally coated with the thermoplastics material,   e) after a time removing each mould and allowing it to cool,   f) opening the mould,   g) and optionally trimming each component so that its dimensions are controlled.   
     
     
         9 . An interlockable range of components; each component having an exterior comprised of a fused thermoplastics material and an interior; each component conforming to standardised dimensions with respect to a complementary interlocking component, characterised in that the components are selected from a range of non-rectangular blocks including a set of components having a triangular outline and a set of components having a hexagonal outline; said blocks being interlockable by tongue and groove joining means provided along each of the edges.