Title: Ventilated interlocking translucent blocks
Abstract: A vented hollow translucent/transparent plastic block for use in wall construction includes a single aperture disposed along the lower edge of the plastic block for alleviating pressure within the plastic block and for discharging any condensation within the plastic block that may occur.
Patent Number: 6,988,341 Issued on 01/24/2006 to Regina
| Inventors:
|
Regina; Samuel R. (3800 S. Cantabria, #1037, Chandler, AZ 85248)
|
| Appl. No.:
|
142306 |
| Filed:
|
May 8, 2002 |
| Current U.S. Class: |
52/306; 52/171.3; 52/591.1; 52/592.2; 52/591.5 |
| Current Intern'l Class: |
E04B 5/46 (20060101) |
| Field of Search: |
52/306,307,589.1,591.1,592.1,578,458,591.5,592.2,604,171.3
|
References Cited [Referenced By]
U.S. Patent Documents
| 4628652 | Dec., 1986 | Wefels.
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| 4807412 | Feb., 1989 | Frederiksen.
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| 4891925 | Jan., 1990 | Carlson et al.
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| 5014479 | May., 1991 | Yeh et al.
| |
| 5033245 | Jul., 1991 | Kline.
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| 5038542 | Aug., 1991 | Kline.
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| 5121575 | Jun., 1992 | DeGarmo et al.
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| 5247773 | Sep., 1993 | Weir.
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| 5259161 | Nov., 1993 | Carter.
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| 5367846 | Nov., 1994 | VonRoenn, Jr.
| |
| 5588271 | Dec., 1996 | Pitchford.
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| 5595033 | Jan., 1997 | Frey.
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| 5778620 | Jul., 1998 | Fisher.
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| 5836125 | Nov., 1998 | Regina.
| |
| 5904019 | May., 1999 | Kooij et al.
| |
| 5910086 | Jun., 1999 | Fisher.
| |
| 5970673 | Oct., 1999 | Fisher.
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| 5987829 | Nov., 1999 | Fisher.
| |
| 6260317 | Jul., 2001 | Fisher.
| |
| 6393786 | May., 2002 | Hudson et al.
| |
Primary Examiner: Friedman; Carl D.
Assistant Examiner: Horton; Yvonne M.
Attorney, Agent or Firm: Cahill, von Hellens & Glazer P.L.C.
Claims
I claim:
1. A vented hollow plastic block for use in a wall section, said plastic block
comprising in combination:
a) a pair of members, each of said members including a continuous side wall,
said side wall of one of said members including a lip and said side wall of the
other of said members including an undercut for receiving and mating with said
lip and forming a junction; and
b) a slot extending into either one of said side walls, said slot being adapted
to be partly covered upon mating of said side walls with one another, the uncovered
part of said slot forming a single vent in said hollow plastic block.
2. The vented hollow plastic block as set forth in claim 1 wherein the said vent
has an area equivalent to a circle having a diameter in the range of about 0.005
inches to about 0.25 inches.
3. The vented hollow plastic block as set forth in claim 2 wherein said vent
has an area equivalent to a circle having a diameter in the range of about 0.012
inches to about 0.015 inches.
4. The vented hollow plastic block as set forth in claim 1 wherein each of said
members is made of translucent plastic material.
5. The vented hollow plastic block as set forth in claim 1 wherein each of said
members is made of transparent plastic material.
6. The vented hollow plastic block as set forth in claim 1 wherein each of said
members is square, wherein said side walls define four edges, and including a snap
fit mechanism disposed in each of said edges and adapted for locking engagement
with a further plastic block placed there against, said slot being disposed proximate
one of said snap fit mechanisms.
7. The vented hollow plastic block as set forth in claim 6 wherein said snap
fit mechanism comprises either a female receptacle or a male coupling and wherein
said female receptacle is disposed on two of said edges and said male coupling
is disposed on the remaining two of said edges.
8. The vented hollow plastic block as set forth in claim 7 wherein each of said
female receptacles comprises a pair of adjacent cylindrical members and wherein
said slot is disposed intermediate said cylindrical members of only one of said
female receptacles.
9. A vented hollow plastic block for use in a wall section, said plastic block
comprising in combination;
a) a pair of members, each of said members including a continuous side wall,
said side wall of one of said members including a lip and said side wall of the
other of said members including an undercut for receiving and mating with said
lip and forming a junction; and
b) a single aperture disposed in either one of said side walls, said aperture
having an area equivalent to a circle having a diameter in the range of about 0.005
inches to about 0.025 inches.
10. The vented hollow plastic block as set forth in claim 9 wherein said aperture
has an area equivalent to a circle having a diameter in the range of about 0.012
inches to about 0.015 inches.
11. The vented hollow plastic block as set forth in claim 9 wherein each of said
members is made of translucent plastic material.
12. The vented hollow plastic block as set forth in claim 9 wherein each of said
members is made of transparent plastic material.
13. The vented hollow plastic block as set forth in claim 9 wherein each of said
members is square, wherein said side walls define four edges, and including a snap
fit mechanism disposed in each of said edges adapted for locking engagement with
a further plastic block placed there against, said aperture being disposed proximate
one of said snap fit mechanisms.
14. The vented hollow plastic block as set forth in claim 13 wherein said snap
fit mechanism comprises either a female receptacle or a male coupling and wherein
said female receptacle is disposed on two of said edges and said male coupling
is disposed on the remaining two of said edges.
15. The vented hollow plastic block as set forth in claim 14 wherein each of
said female receptacles comprises a pair of adjacent cylindrical members and wherein
said aperture is disposed intermediate said cylindrical members of only one of
said female receptacles.
16. A vented hollow translucent/transparent plastic block of use in a wall section,
said plastic block comprising in combination:
a) a pair of members, each of said members including a continuous side wall,
said side walls defining four edges of said plastic block;
b) said side wall of one of said members being in sealed engagement with said
side wall of the other of said members; and
c) a single aperture disposed in either one of said edges, said aperture having
an area equivalent to a circle having a diameter in the range of about 0.005 inches
to about 0.25 inches.
17. The vented hollow translucent/transparent plastic block as set forth in claim
16 wherein said aperture has an area equivalent to a circle having a diameter in
the range of about 0.012 inches to about 0.015 inches.
18. The vented hollow translucent/transparent plastic block as set forth in claim
16 wherein said aperture is formed at the junction of said side walls.
19. An interlockable building block comprising:
a) a block including spaced apart front and rear surfaces having a perimeter
edge and at least three sidewalls spanning the distance between the front and rear
surfaces, the front and rear surfaces being dimensioned such that the perimeter
edge extends outward from the block sidewalls and defines a protruding ledge;
b) a block fastening system including
i) a male coupling element positioned on one of the sidewalls and having a male
interlocking element with a defined maximum width and a pedestal element having
a first end and a spaced apart second end supporting the male interlocking element
at a fixed distance from the block sidewall, the pedestal element having a width
less than the maximum width of the male interlocking element to provide a reduced
width capture zone located in proximity to the male interlocking element; and
ii) a female receptacle positioned on a different one of the sidewalls and including
first and second female interlocking elements and first and second laterally deflectable
female pedestal elements laterally spaced apart along the length of the sidewall,
each pedestal element having a first end coupled to the sidewall and an elevated
second end, the second ends of the female pedestal elements supporting the first
and second female interlocking elements at a fixed distance above the block sidewall
with a lateral spacing less than the maximum width of the male interlocking element,
the female receptacle configured to define a male coupling element engagement chamber
below the spaced apart second ends of the female pedestal elements whereby the
female receptacle laterally deflects around and captures a mateable male coupling
element to provide a snap together interlocking coupling with the mateable male
coupling element; and
c) a single vent disposed in either one of said sidewalls.
20. An interlocking building block assembly comprising:
a) a first block including spaced apart front and rear surfaces having a perimeter
edge and at least three sidewalls spanning the distance between the front and rear
surfaces, the front and rear surfaces being dimensioned such that the perimeter
edge extends outward from the block sidewalls and defines a protruding ledge further
including a block fastening system including a male coupling element positioned
on one of the sidewalls and having a male interlocking element with a defined maximum
width and a pedestal element having a first end and a spaced apart second end supporting
the male interlocking element at a fixed distance from the block sidewall, the
pedestal element having a width less than the maximum width of the male interlocking
element to provide a reduced width capture zone located in proximity to the male
interlocking element;
b) a second block including spaced apart front and rear surfaces having a perimeter
edge and at least three sidewalls spanning the distance between the front and rear
surfaces, the front and rear surfaces being dimensioned such that the perimeter
edge extends outward from the block sidewalls and defines a protruding ledge further
including a block fastening system including a female receptacle positioned on
a different one of the sidewalls and including first and second female interlocking
elements and first and second laterally deflectable female pedestal elements laterally
spaced apart along the length of the sidewall, each pedestal element having a first
end coupled to the sidewall and an elevated second end, the second ends of the
female pedestal elements supporting the first and second female interlocking elements
at a fixed distance above the block sidewall with a lateral spacing less than the
maximum width of the male interlocking element, the female receptacle configured
to define a male coupling element engagement chamber below the spaced apart second
ends of the female pedestal elements whereby the female receptacle on the second
block laterally deflects around and captures the male coupling element on the first
block to provide a snap together interlocking coupling between the first and second
blocks; and
c) a single vent disposed in one of said sidewalls.
21. A hollow rectangular plastic block for installation in a vertical wall section comprising:
a) a pair of rectangular members joined together to form the block, each member
including a continuous end wall and a continuous sidewall, one sidewall member
including a lip and the other sidewall member including an undercut for mating
with the lip to form an airtight seal between the mated sidewall member to define
a sealed interior chamber having a lower sidewall surface, an upper sidewall surface
and vertically oriented left and right sidewall surfaces; and
b) a single vent penetrating upwardly through the lower sidewall surface establishing
a pressure equalizing passageway between the sealed interior chamber and the ambient
atmosphere, the vent representing the only air flow communication path between
the sealed chamber and the ambient atmosphere, the vent having a cross sectional
area equivalent to a circle having a diameter in the range of about 0.005 inches
to about 0.25 inches.
22. The hollow rectangular plastic block of claim 21 wherein the vent is laterally
displaced away from the vertically oriented left and right sidewall surfaces.
23. The hollow rectangular plastic block of claim 22 wherein the vent is located
in a central portion of the lower sidewall.
24. The hollow rectangular plastic block of claim 23 wherein the vent penetrates
substantially vertically upwardly through the lower sidewall.
25. The hollow rectangular plastic block of claim 24 wherein the vent is formed
as a cylindrical passageway.
26. The hollow rectangular plastic block of claim 23 wherein the vent is located
in a central area relative to the vertically oriented block end walls.
27. The hollow rectangular plastic block of claim 24 wherein the vent has a cross
sectional area equivalent to a circle having a diameter in the range of from about
0.012 inches to about 0.015 inches.
28. The hollow rectangular plastic block of claim 21 wherein the block is formed
as a square with parallel top and bottom sidewalls, parallel left and right sidewalls
and parallel end walls.
29. An interlockable hollow, rectangular plastic block for installation in a
vertical wall section, comprising:
a) a hollow rectangular block including vertically oriented, spaced apart front
and rear surfaces having a perimeter edge and vertically oriented left and right
sidewalls and vertically oriented top and bottom sidewalls spanning the distance
between the vertically oriented front and rear surfaces, the front and rear surfaces
being dimensioned such that the perimeter edge extends outward from the block sidewalls
and defines a protruding ledge, the hollow interior of the block defining a sealed
interior chamber having a lower side surface, an upper side surface and vertically
oriented left and right end surfaces; and
b) a single vent penetrating upwardly through the bottom block sidewall establishing
a pressure equalizing passageway between the lower side surface of the sealed interior
chamber and the ambient atmosphere outside the chamber, the vent representing the
only air flow connection path between the sealed chamber and the ambient atmosphere,
the vent having a cross sectional area equivalent to a circle having a diameter
in the range of about 0.005 inches to about 0.25 inches.
30. The interlockable hollow, rectangular plastic block fastening system of claim
29, including:
a) a male coupling element positioned on one side of the sidewalls and having
a male interlocking element with a defined maximum width and a pedestal element
having a first and a spaced apart second end supporting the male interlocking element
at a fixed distance from the block sidewall, the pedestal element having a width
less than the maximum width of the male interlocking element to provide a reduced
width capture zone located in proximity to the male interlocking element; and
b) a female receptacle positioned on a different one of the sidewalls and including
first and second female interlocking elements and first and second laterally deflectable
female pedestal elements laterally spaced apart along the length of the sidewall,
each pedestal element having a first end coupled to the sidewall and an elevated
second end, the second ends of the female pedestal element supporting the first
and second interlocking elements at a fixed distance above the block sidewall with
lateral spacing less than the maximum width of the male interlocking element, the
female receptacle configured to define a male coupling element engagement chamber
below the spaced apart second ends of the female pedestal elements whereby the
female receptacle laterally deflects around and captures a mateable male coupling
element to provide a snapped-together interlocking coupling with a mateable male
coupling element.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to transparent/translucent blocks as building materials
used in commercial and residential construction and, more particularly, to ventilated
interlocking blocks of manmade materials.
2. Description of Related Art
For decades, hollow glass blocks have been used to form interior or exterior
walls or sections thereof in order to permit transmission of light through such
walls. Usually, these glass blocks distort any images viewed therethrough or the
blocks may be translucent to permit passage of light and yet provide a significant
degree of privacy. For example, glass blocks have been used as part of a bathroom
wall to permit transmission of light therethrough, particularly important if there
are no windows in the bathroom, and yet provide privacy. In a commercial or private
environment, walls or wall dividers have been formed of translucent hollow glass
blocks to delineate floor space while accommodating light transmission therethrough
to create a more airy and open environment without compromising privacy.
Hollow glass blocks serve the sought end result very well but several difficulties
are created. First, the glass blocks are relatively heavy and generally are only
permitted to be used under building codes in conjunction with supporting brick
walls; conventional wood frame construction is generally considered of insufficient
structural strength to support glass blocks. Second, transport of the glass blocks
from a point of manufacturer to the end user is generally expensive because of
the weight and the attendant crating and shipping costs. Third, in order to accommodate
the change in pressure within the hollow part of the glass block due to temperature
and elevational changes, the glass walls must be very thick. Fourth, assembling
a wall or wall section of glass blocks requires a skilled artesian to properly
align the glass blocks and to exercise skill in securing the glass blocks to one
another with a binding agent.
To overcome the weight and handling difficulties attendant hollow glass blocks,
hollow blocks of transparent/translucent manmade materials have been developed;
hereinafter referred to as plastic blocks. These plastic blocks generally include
interlocking elements to permit seating and rapid assembly. In some circumstances,
depending upon the configuration and use of the plastic block, a binding agent
must be used. The primary benefits of plastic blocks include light weight, ease
of handling and installation, and relatively low cost.
The plastic blocks are hollow and the interior space is sealed against intrusion
of foreign matter as well as air. In response to temperature changes or changes
in elevation (primarily during shipping), the pressure within the plastic blocks
increases and decreases proportionately. The pressure changes within the plastic
blocks generally result in inward or outward flexing of the walls of the plastic
block. Such flexing creates stresses within the plastic material. During cleaning
with conventional cleaning agents, lines of stress become visually apparent. The
resulting disfiguration becomes permanent and compromises the aesthetics of the
wall or wall section formed of the plastic blocks.
SUMMARY OF THE INVENTION
The present invention is directed to ventilated transparent and/or translucent
hollow plastic blocks having interlocking elements for rapidly building a wall
or a wall section of such plastic blocks. Ventilation of the glass blocks to avoid
imposing stresses on the walls of the glass blocks due to temperature changes and
elevational changes is provided. In particular, equalization of pressure within
each plastic block with the ambient pressure is provided by a single aperture disposed
in the bottom edge of a mounted plastic block.
It is therefore a primary object of the present invention to provide a ventilated
plastic block.
Another object of the present invention is to provide a ventilated translucent
or transparent plastic block for use as a wall section.
Yet another object of the present invention is to provide a ventilated plastic
block having interlocking elements for rapid snap together assembly with adjacent
plastic blocks.
Still another object of the present invention is to provide is to provide a
single aperture for ventilating a plastic block used in the construction of a wall.
A further object of the present invention is to provide a specifically located
aperture in a translucent hollow plastic block to reduce the likelihood of condensation
settling on the interior surfaces of the hollow plastic block.
A yet further object of the present invention is to provide a ventilated plastic
block which precludes airflow therethrough while accommodating inflow and outflow
through a common aperture due to changes in internal pressure resulting from temperature
and elevational changes.
A still further object of the present invention is to avoid creation of stresses
in the side walls of a transparent/translucent hollow plastic block due to temperature
and elevational changes.
A still further object of the present invention is to provide a method for avoiding
stressing the side walls of a hollow plastic block due to temperature and elevational changes.
These and other objects of the present invention will become apparent to those
skilled in the art as the description there proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described with greater specificity and clarity
with reference to the following drawings, in which:
FIG. 1 illustrates a plurality of interlocked plastic blocks;
FIG. 2 is a cross sectional view taken along lines 2—2,
as shown in FIG. 1;
FIG. 3A is a cross sectional view taken along lines 3A—3A,
as shown in FIG. 2;
FIG. 3B illustrates a variant of the ventilation aperture shown in FIG. 3A;
FIG. 4 is a cross sectional view taken along lines 4—4,
as shown in FIG. 3A;
FIG. 5A illustrates the two halves of a plastic lock prior to assembly; and
FIG. 5B is a detailed view of the section encircled and identified with reference
numeral 5B shown in FIG. 5A.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Interlocking unventilated plastic locks have been developed by the applicant,
as illustrated and described in U.S. Pat. No. 5,836,125. The illustrations and
writings contained therein are incorporated by reference herein. Accordingly, many
of the features common with the present invention, particularly with respect to
the interlocking and alignment elements, will be only summarily discussed as the
details thereof are set forth in U.S. Pat. No. 5,836,125.
Referring to FIG. 1 there is shown a plurality of interlocking plastic
blocks
10,
10A and
10B which are preferably, but not necessarily,
of acrylic material. Edge
12 of each plastic block includes two pairs of
alignment tabs
14A,
14B and
16A,
16B. The tabs of each
pair of these pairs of tabs are relatively widely spaced from one another as illustrated.
Opposite edge
18 of plastic block
10 includes two pairs of alignment
tabs of which tabs
15A,
15B are shown; these pairs of tabs are spaced
closer to one another than pairs of tabs
14A,
14B and
16A,
16B.
Edge
20 of each plastic block also includes two pairs of alignment tabs
22A,
22B and
24A,
24B. A spacing between the alignment
tabs of these two pairs of tabs is less than the space between pairs of alignment
tabs
14A,
14B and
16A,
16B and corresponds with the spacing
of pairs of tabs
15A,
15B. Edge
26 of each plastic block includes
two pairs of alignment tabs equivalent in spacing and location to pairs of alignment
tabs
14A,
14B and
16A,
16B. Each of these alignment tabs
bears against the inside surface of a corresponding one of circumferential flanges
30,
32 of an adjacent interlocking plastic block. Moreover, flanges
30,
32 serve as the bearing surfaces between adjacent blocks. Thereby,
plastic blocks
10,
10A and
10B are easily assembled with one
another in perfect alignment to form a wall section, window, divider, etc.
Generally, an assembly of plastic blocks is bounded by structure such
as a strap or the like to ensure stability of the assembled structure wherein the
structure is to be used. Additionally, a frame of wood, metal or other material
may be used as a boundary within which the plastic blocks are mounted. A mastic
or other binding agent may be used to secure the blocks to one another.
As particularly shown in FIG. 2, a snap fit mechanism may be incorporated to
retain
the blocks in place with one another during assembly. As the details of the snap
fit mechanism are further described in U.S. Pat. No. 5,836,125 the following discussion
will be relatively brief. Snap fit mechanism
40 may include a female receptacle
42 to be engaged by a male coupling
44. The female receptacle includes
a pair of cylindrical locking members
46,
48 located at the extremity
of respective wall members
50,
52. Male coupling
44 includes
a cylindrical member
54 supported upon a wall member
56. As shown
in FIG. 2, the spacing between cylindrical members
46,
48 of female
receptacle
44 is less than the diameter of cylindrical member
54
of male coupling
44. To permit penetration therebetween, wall members
50,
52
of the female receptacle are resilient and sufficiently flexible to permit insertion
and removal of the male coupling. As shown in FIG. 1, and other figures, each side
of each plastic block may include a pair of snap fit mechanisms
40. As further
noted in FIG. 1, edge
12 supports a male coupling
44 and opposite
edge
18 supports a female receptacle
42. Edge
20 supports
a female receptacle
42 and opposite edge
26 supports a male coupling
44. Thereby, the plastic blocks will be oriented to locate bottom edge
18
of one plastic block adjacent the top edge of another plastic block. When such
placement occurs, the alignment tabs will be properly mated and the corresponding
snap fit mechanisms will be functional.
As particularly shown in FIGS. 4 and 5A, each of the plastic blocks (
10,
10A,
10B) is formed of two members
60,
62. Member
60
includes a four-sided side wall
64 and member
62 includes a similar
four-sided side wall
66. For structural reasons and to obtain a good bond
between the members, side wall
64 includes a peripheral lip
68 that
mates with a peripheral undercut
70 in side wall
66. Upon mating
and bonding members
60,
62 with one another, an enclosed space is
formed within the two members.
During transport of the plastic blocks, changes of elevation occur. Such changes
of elevation would create a pressure differential between the space interior of
each plastic block and ambient pressure. Unless each plastic block were vented,
such pressure differential would cause the sides of the plastic block to flex in
response to the degree of pressure differential. Similarly, during changes of the
ambient temperature as a result of a plastic block being subjected to solar radiation,
other source of heating or a cooling environment, the temperature within a sealed
plastic block would change with a commensurate increase or decrease in pressure
and the sides of the plastic block would flex in conformance therewith.
One of the reasons for having prior art glass blocks and prior art plastic blocks
sealed is to prevent condensation to develop on the inside surfaces due to a change
in temperature or ambient pressure by preventing air flow through such a block.
However, it has been learned that the plastic blocks of the type illustrated and
described herein can be vented to obviate a pressure differential between the interior
of the plastic block and the ambient pressure and thereby prevent flexing of the
sides of the plastic block. However, such venting must be configured to prevent
cross flow within the plastic block. Furthermore, it has been learned that if the
vent is on the bottom edge, any condensation that may develop, although unlikely,
it can drain through the vent.
Referring particularly to FIGS. 4,
5A and
5B, the vent developed
for use with plastic block
10 will be described. Vent
80, located
in bottom edge
18 of plastic block
10 is formed by a slot
82
extending into side wall
66 past undercut
70. Upon mating of side
walls
64,
66 lip
68 covers a part of slot
82 to the
extent of the width of undercut
70. The resulting vent is particularly shown
in FIGS. 2 and 3A.
Vent
80 accommodates a flow of air into and out of plastic block
10
as a function of changes in pressure outside or inside the plastic block. The vent
is sized small enough to preclude any cross flow of air within the plastic block.
That is, air can not enter at one location and depart at a different location.
With such lack of cross flow within the plastic block, it has been learned that
condensation within the plastic block will almost never occur. Yet, the use of
a single vent of relatively small size will preclude flexing of the sides of the
plastic block causing the stresses that ultimately will become visible upon cleaning
the plastic block with conventional cleaning agents.
FIG. 3B illustrates a variant
90 of vent
80. A simple hole may
be drilled in one or the other side walls of block
10 in edge
18
or may be formed therein during fabrication of the respective member
60/
62.
Under certain circumstances, variant
90 may be formed post manufacturing
by drilling a hole, as illustrated.
By experimentation, it has been learned that the size of vent
80 or variant
90 should have an area equivalent to a round hole having a diameter in the
range of at least about 0.005 inches to about 0.25 inches. Optimally, the size
of vent
80 or variant
90 should have an area equivalent to a circle
having a diameter in the range of about 0.012 inches to about 0.015 inches to minimize
the likelihood of inflow of moisture and yet permit an outflow of moisture if such
inflow does occur. Thereby, an environment of trapped moisture will be eliminated.
These area dimensions were developed as a result of significant testing during
transport of the plastic blocks over roads having varying elevations and by subjecting
them to temperature differentials over a period of time.
While the invention has been described with reference to several particular
embodiments thereof, those skilled in the art will be able to make the various
modifications to the described embodiments of the invention without departing from
the true spirit and scope of the invention. It is intended that all combinations
of elements and steps which perform substantially the same function in substantially
the same way to achieve the same result are within the scope of the invention.
*
