Interlocking asymmetric universal construction block

Abstract

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.

I claim: 
     
         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.