# US 2025/0027316 A1 · Foam as modular support

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- Number: US 2025/0027316 A1
- Document ID: US20250027316A1
- Status: Published application
- Kind: A1
- Application number: 18/906,451
- Filed: 2024-10-04
- Published: 2025-01-23
- Earliest claimed: 2019-11-22
- Assignees: Lazarian World Homes
- Applicants: Lazarian World Homes
- Inventors: George FERMANIAN
- Web page: https://patentgrep.com/patent/US20250027316A1

## CPC

- E04C 1/39: characterised by special adaptations, e.g. serving for locating conduits, for forming soffits, cornices, or shelves, for fixing wall-plates or door-frames, for claustra
- E04B 2/18: by interlocking of projections or inserts with indentations, e.g. of tongues, grooves, dovetails
- E04B 2/24: the walls being characterised by fillings in some of the cavities forming load-bearing pillars or beams
- E04B 2002/0226: {with tongues and grooves next to each other on the end surface}
- E04B 2002/0228: {with tongues next to each other on one end surface and grooves next to each other on opposite end surface}
- E04B 2002/0256: {Special features of building elements}
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})

## 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.

## Claims

### Claim 1

A wall comprising:
a plurality of base blocks stacked to form a bottom portion of the wall, each of the base blocks 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; 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 header blocks further comprise a plurality of mating protrusions each tapering towards an uppermost edge thereof.

### Claim 2 (depends on 1)

The wall of claim 1, wherein the back surface of the header blocks each comprise surface features configured to engage with a front surface of an adjacent header block.

### Claim 3 (depends on 1)

The wall of claim 1, wherein the back surface of the header blocks each comprise a cutout shaped to a profile of the channel.

### Claim 4 (depends on 3)

The wall of claim 3, further comprising:
a beam stop insert positioned at one or both of a front surface and a back surface of at least one of the header blocks within the cutout.

### Claim 5 (depends on 4)

The wall of claim 4, wherein the beam stop insert is positioned at one or both of an end and corner of the wall.

### Claim 6

A wall comprising:
a plurality of base blocks stacked to form a bottom portion of the wall, each of the base blocks 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
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 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.

### Claim 7 (depends on 6)

The wall of claim 6,
wherein the header blocks each comprise six pairs of mating protrusions,
wherein each pair of mating protrusions of the six pairs of mating protrusions comprises opposite mating protrusions extending from each header block sidewall, and
wherein the pairs of mating protrusions are aligned with the cavities of the base blocks.

### Claim 8 (depends on 6)

The wall of claim 6, further comprising:
a header beam extending through the channel.

### Claim 9 (depends on 8)

The wall of claim 8, wherein the header beam extends across at least two header blocks, through a back surface of a first header block of the two header blocks and through a front surface of a second header block of the two header blocks.

### Claim 10 (depends on 6)

The wall of claim 6, further comprising a reinforcing material extending vertically through the cavities across rows of the base blocks.

### Claim 11 (depends on 10)

The wall of claim 10, wherein the reinforcing material comprises a steel rod and concrete.

### Claim 12 (depends on 6)

The wall of claim 6, wherein the header blocks are stacked over the base blocks such that for a majority of the header blocks, the header block is stacked directly on two base blocks.

### Claim 13 (depends on 12)

The wall of claim 12, wherein the header blocks are stacked over the base blocks such that for a majority of the header blocks, the header block is stacked directly on two base blocks.

### Claim 14 (depends on 6)

The wall of claim 6, wherein the recesses are aligned vertically with the cavities.

### Claim 15 (depends on 6)

The wall of claim 6, wherein the bottom portion of the wall comprises multiple rows of the base blocks stacked vertically, and wherein the top portion of the wall comprises only one row of the header blocks.

### Claim 16

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; 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.

### Claim 17 (depends on 16)

The wall of claim 16, wherein at least one of the cavities of a first base block of the plurality of base blocks has a first portion with a first width and a second portion with a second width different from the first width.

### Claim 18 (depends on 17)

The wall of claim 17, wherein the first width is between about four inches and about eight inches and the second width is between about four inches and about six inches.

### Claim 19 (depends on 16)

The wall of claim 16, wherein the cavities of at least a first base block of the plurality of base blocks collectively have a volume of about 47% of a total volume of the first base block.

### Claim 20 (depends on 16)

The wall of claim 16, wherein the polymer foam is polyurethane.