The Keyed Brick System
The Keyed Brick is the basic component inside a construction system with multiple supporting parts. Aside from the basic brick, there will be fourteen ending parts and twelve corner parts totaling twenty seven unique keyed bricks.
The basic Keyed Brick has a core that will be more then 80% of the brick’s mass. It will be a composite of a recycled plastic binder and an aggregate of sand or something hard. The goal is a core that will support a two-story house. In practice the core will be completely entombed sealing its contents.
The technical advantage of an inner core and outer case is predictability. Deformation of the plastic surfaces happens while cooling. By having an inner core that is at least five times more mass, it will absorb the heat of the outer case faster down to below the deformation temperature. This is relative to all the Keyed components.
Ends
The fourteen ending parts are tops, bottoms and sides with left and right components. Corners are more complex. Keyed Bricks assemble in a single counter clockwise motion which works fine for left corners. Right corners have to use a clockwise motion and require clockwise Key Threads. Each corner has an alternating pair that also have to end on top and begin on the bottom. That is six parts per corner totaling twelve.
This wall demonstrates the ending parts:
These are the beginning and ending Keyed Brick parts. Because construction has alternating layers, the ends alternated between half and full bricks. The half brick left and right ends are shown on the outside and the full left and right ends are shown inside the door. The top and bottoms have are half and full bricks for the left and right side; and full bricks in the middle. There are fourteen Keyed Brick parts that build the outer boundaries.
This diagram has the Keyed Brick parts relative to how they are used. The tops are on top; sides on the sides; and bottoms on the bottom.
Left Corner
There are left and right corners. Because of two alternating layers, each corner has two specific corner bricks and two flat sided bricks to butt against totaling four per corner. These come in flat tops and flat bottoms adding eight bricks more totaling twelve unique bricks.
The second layer has the last standard keyed brick at 1. Then a right end keyed brick in position 2. This is important because once the corner brick 3 is in place, 2 cannot be added. 3 is rotated into position and 4 continues the wall.
This completes the first corner layer. The next alternating corner layer starts from here.
At 4 is the last standard brick. At 5 is a flat end brick that has to be installed before 6 can go on. 6 rotates into position.
7 is the continuation of the completed left corner.
Right Corner
The right corner has to rotate clockwise so the corner parts are made with clockwise Key Threads.
The right corner has to have to have more setup parts. Keyed Brick 1 and 3 have clockwise threads. 1 goes first so 3 will be against a flat edge. 2 is a standard brick that 3 engages.
4 continues the completed layer.
5 is the continuation of the wall. 6 has the flat end with clockwise threads. 7 is the corner that will go against the flat end of 6.
8 continues the layer completing the two alternating layers of a right hand corner.
