Polymer-Based Construction Blocks and Methods for Using Them

Abstract

A prefabricated building block is used in the construction of structures. The block is composed of a polymer-based material, with a density of not more than 10 lbs. per cubic foot.

What is claimed is: 
     
         1 . A pre-fabricated building block comprising:
 a frame having an approximately rectangular cuboid shape comprising six faces, the frame composed of a material comprising polyvinyl chloride;   wherein the interior of the frame comprises a hollow space;   wherein the density of the block is less than 10 lbs. per cubic foot; and   wherein the block is configured to interconnect to another block.   
     
     
         2 . The block of  claim 1 , wherein the material of which the frame is composed further comprises at least 6% barium sulfate by weight. 
     
     
         3 . The block of  claim 1 , wherein the block has a density of less than 4 lbs. per cubic foot. 
     
     
         4 . The block of  claim 1 , wherein the material of which the frame is composed comprises at least 20% polyvinyl chloride by weight. 
     
     
         5 . The block of  claim 1 , wherein the block has a volume of at least 0.07 cubic feet. 
     
     
         6 . The block of  claim 1 , wherein the block further comprises:
 substantially uniform and uninterrupted sidewalls on at least two of the block faces;   at least one block face comprising a male interlocking feature;   at least one block face comprising a female interlocking feature;   at least two block faces each comprising an opening covering at least 25% of the surface area of each of the at least two block faces.   
     
     
         7 . The block of  claim 1 , wherein the material of which the frame is composed further comprises a UV inhibitor. 
     
     
         8 . The block of  claim 1 , wherein the hollow space comprises at least 50% of the total volume occupied by the block. 
     
     
         9 . A polymer-based block for construction of walls or buildings, comprising:
 an interlocking feature;   wherein the block has a density of less than 10 lbs. per cubic foot.   
     
     
         10 . The block of  claim 9 , wherein the block comprises at least one surface that is textured to be substantially rough. 
     
     
         11 . The block of  claim 10 , wherein the block is substantially in the shape of a rectangular cuboid, the block further comprising:
 a substantially flat surface opposite the face comprising the interlocking feature;   wherein the block is configured to act as a plug or a cap when coupled to a second block having at least one open face.   
     
     
         12 . The block of  claim 10 , further comprising a receptacle for glass. 
     
     
         13 . The block of  claim 10 , further comprising a receptacle for a junction box. 
     
     
         14 . The block of  claim 10 , further comprising an integrated junction box. 
     
     
         15 . The block of  claim 10 , further comprising at least one curved surface;
 wherein the block forms an arch when coupled with one or more other blocks.   
     
     
         16 . The block of  claim 10 , wherein the block is composed of a material having reduced density due to foaming of its polymer-based material during fabrication. 
     
     
         17 . The block of  claim 10 , wherein the block is composed of a material comprising at least 20% polyvinyl chloride by weight. 
     
     
         18 . The block of  claim 10 , wherein the block is composed of a material comprising barium sulfate, novaculite, chopped strand glass fibers, ethylene vinyl acetate and ammonium laureth sulfate. 
     
     
         19 . A method of manufacturing a block for use as a structural component, comprising:
 foaming a material comprising at least 20% polyvinyl chloride; and   forming the material into the shape of the desired block;   wherein the block has a resulting density of less than 10 lbs. per cubic foot.   
     
     
         20 . The method of  claim 19 , wherein the block is formed via injection molding.