Locking Blocks and Methods for Using Them

Abstract

Disclosed herein are products and methods of using the products for constructing walls and other structures. The product is a locking block designed to be used to quickly and inexpensively erect walls and other structures. The locking block is made from a polymer to form a rigid physical structure that resists damage and provides a relatively clean workspace during assembly. The locking block includes matching male and female structural members that reversibly lock the blocks together and are self-aligning to guide workers regarding block placement during assembly. The block's design eliminates the need to apply mortar or other adhesives to secure the blocks together, thereby significantly reducing labor costs compared to conventional construction products and methods. Because no mortar or other adhesives are used, the blocks can be efficiently and effectively disassembled and reused.

Description

[Technical Field]

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 379,491, filed October 14, 2022, entitled "Locking Block and Methods of Using Same," which is incorporated herein by reference.

[0002] The present disclosure relates generally to blocks that can be fastened together to form an assembly, and more particularly to reusable blocks that include features that allow the blocks to be reversibly fastened together to form a temporary assembly that can be efficiently assembled and disassembled without modification or damage to the blocks. [Background technology]

[0003] Walls and structures are often constructed using blocks made from cement and aggregates such as sand and gravel, with optional cinder, such as fly ash or bottom ash. Such blocks are commonly referred to as cinder blocks. The cinder blocks are made to size and secured together by skilled workers using mortar applied between the cinder blocks. While the use of cinder blocks is very common, there are significant drawbacks to using this product. While cinder blocks are relatively inexpensive to produce, the labor costs of skilled workers assembling a wall or structure by applying mortar to each and every cinder block in the assembly can be very high. Because cinder blocks are relatively fragile, large numbers of blocks that are damaged during storage, transportation, handling, or during the construction of the wall or structure can significantly increase costs. Additionally, employees must manually place each cinder block within a wall or other structure, and if employees are not sufficiently skilled, misalignment or other problems in manually placing the cinder blocks can cause the wall or structure to deviate from the planned placement and dimensions. Furthermore, cinder blocks are a single-use product. Because cinder blocks are attached using mortar, upon completion of any project, the wall or structure is permanent and the blocks are not reusable.

[0004] There is a need in the building industry for products for constructing walls and structures that are reusable, can be efficiently assembled without requiring skilled manual labor, can be efficiently disassembled when the structure is no longer needed, and are durable enough to prevent damage to the product during storage, transportation, or use. This disclosure describes such products and methods for assembling such products. Summary of the Invention [Means for solving the problem]

[0005] Disclosed herein are products and methods of using the products for constructing walls and other structures. The product is a locking block designed to be used to quickly and inexpensively erect walls and other structures. The locking block is made from a polymer to form a rigid physical structure that resists damage and provides a relatively clean workspace during assembly. In one embodiment, the locking block is made using a projectile-molding process to form a lighter locking block. The locking block includes matching male and female features that reversibly lock the blocks together and are self-aligning to guide workers regarding block placement during assembly. In one embodiment, the top surface of the locking block includes six male features and six female features, and the bottom surface of the locking block similarly includes six male features and six female features. This block design eliminates the need to apply mortar or other adhesive methods to secure the blocks together, thereby significantly reducing labor costs compared to typical construction products and methods. Because no mortar or other adhesives are used, the blocks can be efficiently and effectively disassembled and reused.

[0006] The accompanying drawings show structures that, together with the detailed description provided below, illustrate example embodiments of the disclosed systems, methods, and apparatus. Where appropriate, like elements are designated with the same or similar reference numerals. Elements shown as a single component may also be replaced by multiple components. Elements shown as multiple components may also be replaced by a single component. The drawings may not be to scale. The proportions of certain elements may be exaggerated for illustrative purposes. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a schematic perspective view of an exemplary locking block from the top right. [Figure 2] FIG. 2 is a schematic perspective view of the locking block of FIG. 1, seen from the bottom left. [Figure 3] 2 is a schematic top view showing the locking block of Figure 1. [Figure 4A] 4 is a schematic detail view identified in FIG. 3 showing a first male feature on the top side of the locking block of FIG. 1. [Figure 4B] FIG. 4 is another schematic detail identified in FIG. 3 showing the first male feature on the top side of the locking block of FIG. 1. [Figure 5A] FIG. 4 is a schematic detail view identified in FIG. 3 showing a second male feature on the top side of the locking block of FIG. 1. [Figure 5B] FIG. 4 is another schematic detail identified in FIG. 3 showing a second male feature on the top side of the locking block of FIG. 1. [Figure 6] 4 is a schematic detail identified in FIG. 3 showing the female feature on the top side of the locking block of FIG. 1. [Figure 7] FIG. 2 is a schematic bottom view showing the locking block of FIG. 1. [Figure 8A] 8 is a schematic detail identified in FIG. 7 showing the male structure on the bottom side of the locking block of FIG. 1. [Figure 8B] FIG. 8 is another schematic detail identified in FIG. 7, showing the male structure on the bottom side of the locking block of FIG. 1. [Figure 9] 8 is a schematic detail identified in FIG. 7 showing a first female feature on the bottom side of the locking block of FIG. 1. [Figure 10A] 8 is a schematic detail identified in FIG. 7 showing a second female feature on the bottom side of the locking block of FIG. 1. [Figure 10B] 8 is another schematic detail identified in FIG. 7, showing a second female feature on the bottom side of the locking block of FIG. 1. [Figure 11] FIG. 2 is a schematic diagram showing the normal construction of a single block wall using the locking blocks of FIG. 1, with the blocks in the second row shown semi-transparent to better show the details of the engagement of the male and female structures. [Figure 12] FIG. 2 is a schematic diagram showing the normal construction of a single block wall corner using the locking blocks of FIG. 1, where the blocks in the second row are shown semi-transparent to better show the details of the engagement of the male and female features. [Figure 13] FIG. 2 is a schematic diagram showing the normal construction of a double block wall using the locking blocks of FIG. 1, with the blocks in the second row shown semi-transparent to better show the details of the engagement of the male and female structures. [Figure 14] Schematic diagram showing a 90 degree wall with sand and / or vertical support rods placed within a rocking block. DETAILED DESCRIPTION OF THE INVENTION

[0008] The devices, systems, arrangements, and methods disclosed herein are described in detail by way of example with reference to the figures. It will be recognized that modifications to the disclosed and described examples, arrangements, configurations, components, elements, devices, methods, materials, and the like may be made and may be desired for particular applications. In this disclosure, any specification of a particular technique, arrangement, method, and the like may relate to the particular example presented or may merely be a general description of such technique, arrangement, method, and the like. Specific details or specification of examples are not intended to be, and should not be construed as, essential or limiting unless specifically designated as such. Below, selected examples of locking blocks and methods for assembling locking blocks are disclosed and described in detail with reference to Figures 1 through 14.

[0009] Disclosed herein are new and innovative locking blocks for use in reversibly, inexpensively, and efficiently constructing walls and other structures. The locking blocks include an interlocking mechanism that allows for stacking and locking of the blocks in a row on top of each other. The interlocking mechanism includes male and female features on the top and bottom of each block that align the blocks as they are assembled and reversibly lock the blocks together without the need for mortar or any other adhesive. This design of the locking block, including the interlocking mechanism, allows for stacking of blocks in a single-wall configuration, stacking of blocks in a double-wall configuration, and creation of 90-degree corners in both single-wall and double-wall configurations.

[0010] Locking blocks can be made from a wide variety of materials. In one example, the locking block is made from one or more polymers using an injection molding process or a foam injection molding process. The locking block can be injection molded using recycled polymeric materials. In other examples, the locking block can be produced through compression molding, additive manufacturing, or any number of other processes. Other materials that can be used to make the locking block include thermoplastic polymers, blends of thermoplastic polymers, thermoset resins, polystyrene, styrene acrylonitrile (SAN), polycarbonate, polypropylene, polyethylene, blends of polypropylene and polyethylene, elastomers, wood, and the like. Additives such as minerals, organic additives, pigments, elastomers, and crosslinkers can also be used.

[0011] As noted above, the present locking block design eliminates the need for mortar or other adhesives to secure the locking blocks together, thereby significantly reducing labor costs compared to conventional construction products and methods. Because mortar or other adhesives are not used, the blocks can be easily disassembled and reused. An advantage of the locking blocks described herein is their light weight compared to traditional lightweight concrete blocks. Another advantage is that the locking blocks are environmentally friendly, being made entirely from recyclable materials and thus recyclable at the end of their useful life. Other advantages include the fact that polymeric materials, especially those made from foamed polymers, are inherently heat-resistant, offering significantly greater heat resistance than traditional lightweight concrete block materials; the fact that polymeric materials are resistant to harsh weather conditions, including rain and snow; the fact that coatings, such as fire-resistant coatings, can be easily applied to the locking blocks using a primer; and the fact that polymeric locking blocks can be cut using conventional cutting techniques to accommodate specific situations.

[0012] FIGS. 1 through 10 illustrate an exemplary locking block 100. FIG. 1 illustrates a top perspective view of the locking block 100, and FIG. 2 illustrates a bottom perspective view of the locking block 100. FIG. 3 illustrates a top view of the locking block 100, and FIGS. 4A, 4B, 5A, 5B, and 6 illustrate enlarged perspective views of features on the top surface of the locking block 100. FIG. 7 illustrates a bottom view of the locking block 100, and FIGS. 8, 9A, 9B, 10A, and 10B illustrate enlarged perspective views of features on the bottom surface of the locking block 100. As shown in the figures, the top and bottom surfaces of the locking block 100 include a combination of male and female features that interlock to form a secure locking mechanism. It will be understood that terms such as "top," "bottom," "upper," and "lower" are used solely with reference to the figures presented and for ease of description of the locking block 100. These terms may be substituted without departing from the disclosure herein.

[0013] The locking block 100 includes an outer shell with four walls: a pair of opposing long walls 105 and a pair of opposing short walls 110 that combine to form a rectangular outer shell. In the embodiment shown in FIGS. 1-10 , the locking block 100 includes the long walls 105 that are longer than the short walls 110, thereby forming a rectangle. However, it will be appreciated that the locking block may also be configured such that all four walls are of equal length, thus forming a square-shaped locking block. The exemplary locking block 100 further includes a central wall 115 disposed at the midpoint of and connecting the long walls 105. The central wall includes a top surface 117 (best seen in FIG. 1 ) and a bottom surface 118 (best seen in FIG. 2 ). The top surface 117 is recessed from the top surface of the locking block 100 and functions as a female feature, as will be described later. The bottom surface 118 is recessed from the bottom surface of the locking block 100. It will be appreciated that the central wall 115 improves the strength and stability of the locking block 100 .

[0014] As best shown in FIGS. 1 and 3-6, the top surface of the locking block 100 includes six protrusions extending upward from the top surface. These protrusions are also referred to as "male features." There are four male features 125 extending upward from the four corners of the top surface of the locking block 100. These male features 125 are generally cubic shaped with two opposite truncated corners. That is, two of the cube's four corners are curved (as best shown in FIGS. 4A and 4B). A first curved corner 130 of the male feature 125 faces inward relative to the locking block 100, and a second curved corner 135 of the male feature 125 faces outward relative to the locking block 100. In the illustrated example, the radius of the first curved corner 130 is greater than the radius of the second curved corner 135. In one example, the radius of the first curved corner 130 is between about 0.25 inches and 0.75 inches, with one embodiment including a first curved corner 130 having a radius of about 0.50 inches. In one example, the radius of the second curved corner 135 is between about 0.10 inches and 0.40 inches. In one embodiment, the radius of the second curved corner 135 is about 0.13 inches, and in another embodiment, the radius of the second curved corner 135 is about 0.30 inches.

[0015] Two additional male structures 140 are positioned at the midpoint of the long wall 105. These male structures 140 are generally rectangular parallelepipeds (i.e., "rectangular cubes") with all four corners truncated (i.e., curved, as best shown in FIGS. 5A and 5B). The sides of the male structures 140 that are parallel to the long wall 105 are longer than the sides of the male structures 140 that are perpendicular to the long wall 105. In the illustrated example, the two corners 145 facing toward the interior of the locking block have radii that are equal to each other and greater than the radii of the two corners 150 (also equal to each other) facing toward the exterior of the locking block 100. In one example, the radius of the first curved corner 145 is approximately between 0.25 inches and 0.75 inches, with one embodiment including a first curved corner 145 having a radius of approximately 0.50 inches. In one example, the radius of the second curved corner 150 is between 0.10 inches and 0.40 inches. In one embodiment, the radius of the second curved corner 150 is approximately 0.13 inches, and in another embodiment, the radius of the second curved corner 150 is approximately 0.30 inches.

[0016] The top surface further includes six recesses that extend downward from the top surface of the locking block 100 and into the walls 105, 110 of the locking block 100. Each of these recesses is also referred to as a "female feature." There is one female feature 155 located along the top surface of each short wall 110 and two female features 160 located along the top surface of each long wall 110. All six female features 160 are generally rectangular in shape (as viewed from a top perspective view) and are sized and shaped to be identical. In the case of the female structures 155 located on the short walls 110, the female structures 155 are bounded at each opposite end by one of the male structures 125 located at the corners of the locking block 100, bounded on the side facing the interior of the locking block 100 by a wall 165, and unbounded (i.e., open) on the side facing the exterior of the locking block 100. In the case of the female structures 160 located on the long walls 105, each female structure 160 is bounded at one end by a male structure 125 located at the corner of the locking block 100 and bounded at the opposite end by a male structure 140 located at the midpoint of the long wall 105. The female structures are further bounded by the wall 165 of the locking block 100, with the front portion of the female structure 160 being unbounded (i.e., open). As shown in FIG. 6, the interior corner 170 of the female feature 160 is curved, with the radius of the interior corner 170 being between about 0.10 inches and 0.40 inches. In one embodiment, the interior corner 170 is about 0.3 inches. In another embodiment, the interior corner 170 is about 0.13 inches.

[0017] The bottom surface is substantially a mirror image of the top surface. As best shown in Figures 2 and 7-10B, the bottom surface of the locking block 100 includes six protrusions 175 extending downward from the bottom surface. These protrusions are also referred to as "male features." The male features 175 are generally rectangular with truncated corners and are shaped and sized so that all six male features 175 are identical. There is one male feature 175 located on each short wall 110 and two male features 175 located on each long wall 105. The male feature 175 on each short wall 110 is centrally located, and the pair of male features 175 on each long wall 105 are side-by-side and separated by female features (as further described herein). As shown in Figures 8A and 8B, the two corners 180 of the inward-facing male feature 175 of the locking block 110 have a radius that is larger than the radius of the corners 185 of the outward-facing male feature 170. In one example, the radius of the inward-facing corners 180 is between 0.10 inches and 0.40 inches. In one embodiment, the inward-facing corners 180 have a radius of 0.30 inches. The radius of the outward-facing corners 185 is between approximately 0.10 inches and 0.40 inches, with one embodiment having a radius of 0.13 inches.

[0018] There are four female features 190 located at each of the four corners of the bottom side of the locking block 100. As shown in FIG. 9, the female features 190 are bounded on two sides by the male features 175 and walls 165 of the locking block 100 and are unbounded (i.e., open) on the two sides facing outward from the locking block 100. The interior corners 195 of the female features are curved, and the two exterior corners 200 of the female features are curved. In one example, the radius of the interior corners 195 is between about 0.10 inches and 0.40 inches, with one embodiment having a radius of about 0.30 inches. The radius of the outer corners 200 is between about 0.10 inches and 0.40 inches, with one embodiment having a radius of about 0.13 inches.

[0019] One female feature 205 is located at the midpoint of each long wall 105. As shown in Figures 10A and 10B, the female feature 205 is bounded on two opposite sides by the male features 175, bounded on the side facing the interior of the locking block 100 by the interior wall 165 of the locking block 100, and unbounded (i.e., open) on the side facing away from the locking block 100. The interior corners 210 of the female features 205 are curved and have a radius between about 0.10 inches and 0.40 inches. In one embodiment, the radius of the interior corners is 0.30 inches. The radius of the exterior corners 215 of the female feature 205 is between about 0.10 inches and 0.40 inches, with one embodiment having a radius of the exterior corners 215 that is about 0.26 inches.

[0020] A male structure located on the top side of the locking block 100 and a female structure located on the bottom side of the locking block 100 are configured to engage with one another. Additionally, a male structure located on the bottom side of the locking block 100 and a female structure located on the top side of the locking block 100 are configured to engage with one another. The shape, size, and overall dimensions of the male and female structures, including the truncated and curved corners, are adapted to reversibly secure the locking blocks 100 together to form a wall or other assembly, and during assembly, the locking blocks 100 will self-align to assist an operator in positioning the locking blocks 100 during assembly.

[0021] In one example, the overall dimensions of the locking block 100 are 18 inches in length (i.e., along the long wall 105), 9 inches in width (i.e., along the short wall 110), and 12 inches in height. These dimensions do not include the top and the male features protruding from the top surface. The long wall 105 and the short wall 110 are each approximately between 0.65 inches and 1.5 inches thick, and in one embodiment, are 1.125 inches thick. The center wall 115 is approximately between 0.50 inches and 1.25 inches thick, and in one embodiment, is 1 inch thick. The male features 125 located at the corners of the locking block 100 are approximately 1 inch in length and width (excluding the curved corners), and the male feature 135 located at the midpoint of the long wall 105 is approximately 1 inch in width and 2 inches in length (excluding the curved corners).

[0022] FIG. 11 shows the beginning of wall assembly using the locking blocks 100 described herein. One locking block is stacked on top of a pair of locking blocks, where the female and male structural portions are engaged. Such an arrangement can be used to form a single block wall. As shown, the locking blocks in the second row are horizontally offset by half the length of the block, similar to any conventional bricklaying process. This arrangement continues with each subsequent row of locking blocks.

[0023] Figure 12 shows the placement of 90-degree corners in the locking blocks. As shown, two locking blocks in the bottom row are positioned at a 90-degree angle, and in the top row, one locking block is positioned straddling two locking blocks in the bottom row, where the male and female structures are engaged. Figure 13 shows an example of a double-wall configuration with two parallel rows forming the bottom row and the locking blocks in the second row positioned at a 90-degree angle to the bottom row, thereby providing a more robust and stable wall. As shown in Figure 14, the locking blocks allow for the addition of sand or vertical support rods, which strengthen and stabilize the wall without affecting its ability to be easily and efficiently disassembled.

[0024] As shown in Figures 11-14, when an offset construction method is utilized (i.e., the locking blocks are horizontally offset by half the length of the block in vertically adjacent rows and at 90-degree corners), the male and female features are then mated in pairs. A male feature identified as 125 at the top of locking block 100 mates with a female feature identified as 205 at the bottom of locking block 100 (or mates with a female feature identified as 190 at a 90-degree corner). As shown in Figure 11, two male features 125 are positioned side-by-side within one female feature 205. A male feature identified as 140 on the top of the locking block 100 mates with a pair of female features identified as 190 on the bottom of the locking block (each one female feature 190 is a female feature from each adjacent locking block in the lower row). A female feature identified as 155 on the top of the long wall 150 of the locking block 100 mates with a male feature identified as 175 on the bottom of the long wall 105 of the locking block 100. A male feature 175 on the bottom of the short wall 110 mates with the top surface 117 of the center wall 115, which serves as a female feature to receive the two male features 175 on the short walls 110 of the two locking blocks. A female feature 155 on the top of the short wall 110 engages the bottom surface 118 of the central wall 115 .

[0025] An additional advantage of the rocking blocks disclosed herein compared to prior art lightweight concrete blocks is the reduced weight and improved mechanical properties of a comparable sized product. The estimated weight of a wall constructed from conventional concrete lightweight concrete blocks is approximately 1.508 kPa (31.5 lb / ft). 2 ) when using the locking block described herein, compared to approximately 0.704 kPa (14.7 lb / ft 2). Thus, equivalent walls can be constructed using the locking blocks disclosed herein at approximately 50% less weight. Such a configuration significantly reduces the cost of transporting the locking blocks and makes them easier to handle during the construction and demolition of walls or structures. Individual lightweight concrete blocks weigh approximately 40 lb (18.1 kg) to 45 lb (20.4 kg). Contemplated locking blocks fabricated using a foam injection molding process can weigh as little as 22 lb (10.0 kg).

[0026] In terms of mechanical properties, rocking blocks made from polystyrene or recycled polystyrene have superior mechanical properties to conventional lightweight concrete blocks. For example, in terms of compressive strength tested according to ASTM C67, rocking blocks made from polystyrene have a compressive strength of 24.9 MPa (3610 pounds per square inch (psi)); rocking blocks made entirely from recycled polystyrene have a compressive strength of approximately 23.4 MPa (3390 psi); and conventional lightweight concrete blocks have a compressive strength of approximately 17.7 MPa (2560 psi). For example, in terms of maximum load tested according to ASTM C67, rocking blocks made from polystyrene have a maximum strength of approximately 1277 kN (286,995 pounds-force (lbf)); rocking blocks made entirely from recycled polystyrene have a maximum strength of approximately 1199 kN (269,505 lbf); and conventional lightweight concrete blocks have a maximum strength of approximately 677 kN (152,160 lbf). For example, when tested for water absorption according to ASTM C67, rocking blocks made from polystyrene have a water absorption rate of approximately 0.63%; rocking blocks made from 100% recycled polystyrene have a water absorption rate of approximately 0.79%; and conventional lightweight concrete blocks have a water absorption rate of approximately 8.08%. Other suitable properties of polystyrene locking blocks include, for example: fastener strength (using ASTM D6117) of 2.46 kN (553 lbf) required to pull out a #10 x 1 inch screw at 2 / 3 depth; creep measurement of 0.83% at 10 years and 2.07 MPa (300 psi) and 1.47% at 10 years and 4.14 MPa (600 psi) (using ASTM D2990-17); and UV resistance (using ASTM G154) of ΔE=0.54 at 60°C for 8 hours and 50°C for 4 hours at concentration.

[0027] As described, the present interlocking mechanism provides a temporary wall or structure that can be quickly and efficiently constructed and then dismantled and removed after fulfilling its usefulness. Additionally, no damage occurs to the locking block during disassembly, allowing the locking block to be reused for additional projects. The present locking block is well suited for use in emergency and temporary situations, such as military, medical applications, and natural disasters.

[0028] The foregoing description of the examples has been presented for purposes of illustration and description. It is not intended to be comprehensive or limited to the precise form described. Many modifications are possible in light of the above teachings. Some of these modifications have been contemplated, and others will be apparent to those skilled in the art. The examples have been chosen and described in order to best explain the principles of the various examples as suited to the particular uses contemplated. Of course, the scope is not limited to the examples described herein, but may be employed by those skilled in the art in any number of applications and equivalent devices.

Claims

1. a first wall having a top surface and a bottom surface; a second wall disposed opposite the first wall and having a top surface and a bottom surface; a third wall having a top surface and a bottom surface disposed perpendicular to the first wall and the second wall and connecting the first wall to the second wall; a fourth wall having a top surface and a bottom surface disposed opposite the third wall and perpendicular to the first wall and the second wall, connecting the first wall to the second wall; a first male structure disposed on the top surface of the first wall; a second male feature disposed on the top surface of the second wall; a third male structure disposed at an intersection of the top surface of the first wall and the top surface of the third wall; a fourth male structure disposed at an intersection of the top surface of the first wall and the top surface of the fourth wall; a fifth male structure disposed at an intersection of the top surface of the second wall and the top surface of the third wall; a sixth male structure disposed at an intersection of the top surface of the second wall and the top surface of the fourth wall; a first female feature disposed within the top surface of the first wall and positioned between the first male feature and the third male feature; a second female feature disposed within the top surface of the first wall and positioned between the first male feature and the fourth male feature; a third female feature disposed within the top surface of the second wall and positioned between the second male feature and the fifth male feature; a fourth female feature disposed within the top surface of the second wall and positioned between the second male feature and the sixth male feature; a fifth female feature disposed within the top surface of the third wall and positioned between the third male feature and the fifth male feature; a sixth female feature disposed within the top surface of the fourth wall and positioned between the fourth male feature and the sixth male feature.

2. a seventh female feature disposed within the bottom surface of the first wall; and an eighth female feature disposed within the bottom surface of the second wall; and a ninth female structure disposed at an intersection of the bottom surface of the first wall and the bottom surface of the third wall; a tenth female structure disposed at an intersection of the bottom surface of the first wall and the bottom surface of the fourth wall; an eleventh female structure disposed at an intersection of the bottom surface of the second wall and the bottom surface of the third wall; a twelfth female structure disposed at an intersection of the bottom surface of the second wall and the bottom surface of the fourth wall; a seventh male structure disposed on the bottom surface of the first wall and positioned between the sixth female structure and the ninth female structure; an eighth male structure disposed on the bottom surface of the first wall and positioned between the seventh female structure and the tenth female structure; a ninth male structure disposed on the bottom surface of the second wall and positioned between the eighth female structure and the eleventh female structure; a tenth male structure disposed on the bottom surface of the second wall and positioned between the seventh female structure and the twelfth female structure; an eleventh male structure disposed on the bottom surface of the third wall and positioned between the ninth female structure and the eleventh female structure; 2. The locking block of claim 1, further comprising a twelfth male feature disposed on the bottom surface of the fourth wall and positioned between the tenth female feature and the twelfth female feature.

3. 3. The locking block of claim 2, wherein the length of said first wall is equal to the length of said second wall, and the length of said third wall is equal to the length of said fourth wall.

4. 4. The locking block of claim 3, wherein the length of said first wall and said second wall is greater than the length of said third wall and said fourth wall.

5. 2. The locking block of claim 1, wherein said first male feature is located at a horizontal midpoint of said first wall and said second male feature is located at a horizontal midpoint of said second wall.

6. 3. The locking block of claim 2, wherein said seventh female feature is located at the horizontal midpoint of said first wall and said eighth female feature is located at the horizontal midpoint of said second wall.

7. 3. The locking block of claim 2, wherein the third male formation, the fourth male formation, the fifth male formation, and the sixth male formation are generally cubical in shape.

8. 3. The locking block of claim 2, wherein said first male formation and said second male formation are generally cubical in shape.

9. The locking block of claim 2 further comprising a central wall extending from a midpoint of said first wall to a midpoint of said second wall.

10. The locking block of claim 1 , wherein the locking block is made from a polymer.

11. 11. The locking block of claim 10, wherein substantially all of the polymer is recycled polymer.

12. The locking block of claim 10, wherein the polymer is at least one thermoplastic polymer.

13. 13. The locking block of claim 12, wherein the polymer is a blend of two or more thermoplastic polymers.

14. 11. The locking block of claim 10, wherein the polymer is polystyrene.

15. 15. The locking block of claim 14, wherein mineral particles are added to the polystyrene.

16. 11. The locking block of claim 10, wherein the polymer is polycarbonate.

17. The locking block of claim 10 wherein the polymer is SAN.

18. The locking block of claim 10, wherein the polymer is polypropylene.

19. 12. The locking block of claim 11, wherein the process used to make the locking block is an injection molding foam process.

20. 12. The locking block of claim 11, wherein the locking block can be cut using conventional cutting techniques.

Images