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US 12,134,894 B2Granted
Foam as modular support
AssigneeLazarian World Homes
InventorGeorge Fermanian
Life of this patent
Estimating the term…
Abstract
A polyurethane foam block can include a base having a plurality of recesses and a top surface having a plurality of connective components protruding outward from the top surface where each connective component of the plurality of connective components can align with a recess of the plurality of recesses. The polyurethane foam block can include a plurality of sidewalls extending upward from the base and defining an interior and a plurality of partitions extending from the base to the top surface to divide the block into a plurality of cavities. A wall can include base blocks and header blocks. The header blocks can be shaped and constructed similarly to the base blocks with one exception being the header blocks can include an-upward facing channel cutout. The wall can include a beam extending through channels of header blocks.
Claims19
A wall comprising:
- a plurality of base blocks stacked to form a bottom portion of the wall, each of the base blocks having a respective block volume and comprising a bottom surface, a top surface, a front surface, a back surface, sidewalls, and cavities extending through each base block from the bottom surface of the base block to the top surface of the base block, the cavities being aligned vertically across rows of the base block and having a collective cavity volume of about 47% of the respective block volume, with each of the cavities having a width of about four inches to about eight inches;
- and
- a plurality of header blocks stacked on a top row of the base blocks to form a top portion of the wall, each of the header blocks comprising a bottom surface configured to mate with the top surface of the base blocks, a front surface, a back surface, sidewalls, and an upward-facing channel positioned between the sidewalls of the header block,
- wherein the base blocks and the header blocks are each composed of a polymer foam, and
- wherein the sidewalls of the base blocks and the sidewalls of the header blocks each have uniformly smooth exterior surfaces and the header blocks further comprise a plurality of mating protrusions each tapering towards an uppermost edge thereof.
2 more elements
A wall comprising:
- a plurality of base blocks stacked to form a lower section of the wall, each of the base blocks comprising a bottom surface, a top surface, a front surface, a back surface, sidewalls, and six cavities extending through each base block from the bottom surface of the base block to the top surface of the base block, the cavities being aligned vertically across rows of the base blocks with each of the cavities having a width of about four inches to about eight inches;
- and
- a plurality of header blocks stacked on a top row of the base blocks to form a top portion of the wall, each of the header blocks comprising a bottom surface configured to mate with the top surface of the base blocks, a front surface, a back surface, sidewalls, and an upward-facing channel positioned between the sidewalls of the header block,
- wherein each of the header blocks comprise six mating protrusions extending from a top surface of each of the sidewalls, each of the six mating protrusions being vertically aligned with a respective cavity of the six cavities of the base blocks, wherein the mating protrusions of the header blocks each taper towards an uppermost edge thereof,
- wherein each of the base blocks comprise connective components extending upward from the top surface of the base block,
- wherein each bottom surface of the header blocks comprises recesses configured to receive the connective components of the base blocks,
- wherein the sidewalls of the base blocks and the sidewalls of the header blocks each have uniformly smooth exterior surfaces, and
- wherein the base blocks and the header blocks are each composed of a polymer foam.
5 more elements
A wall comprising:
- a plurality of base blocks stacked to form a bottom portion of the wall, each of the base blocks having a block width and comprising a bottom surface, a top surface, a front surface, a back surface, sidewalls, and cavities extending through each base block from the bottom surface of the base block to the top surface of the base block, the cavities being aligned vertically across rows of the base blocks and each cavity having a cavity width that is about half of the block width;
- and
- a plurality of header blocks stacked on a top row of the base blocks to form a top portion of the wall, each of the header blocks comprising a bottom surface configured to mate with the top surface of the base blocks, a front surface, a back surface, sidewalls, and an upward-facing channel positioned between the sidewalls of the header block,
- wherein each of the header blocks comprise mating protrusions extending from a top surface of each of the sidewalls that are vertically aligned with the cavities of the base blocks, wherein the mating protrusions of the header blocks each taper towards an uppermost edge thereof,
- wherein each of the base blocks comprise connective components extending upward from the top surface of the base block,
- wherein the sidewalls of the base blocks and the sidewalls of the header blocks each have uniformly smooth exterior surfaces,
- wherein each bottom surface of the header blocks comprises recesses configured to receive the connective components of the base blocks, and
- wherein the base blocks and the header blocks are each composed of a polymer foam.
5 more elements
Dependencies are inferred from the claim text.