U.S. patent application number 10/806592 was filed with the patent office on 2005-01-13 for composite building block having moisture barrier and insulation element.
Invention is credited to Collier, Judi, Collier, Peter.
Application Number | 20050005556 10/806592 |
Document ID | / |
Family ID | 31500394 |
Filed Date | 2005-01-13 |
United States Patent
Application |
20050005556 |
Kind Code |
A1 |
Collier, Peter ; et
al. |
January 13, 2005 |
Composite building block having moisture barrier and insulation
element
Abstract
A construction block for use in the construction of elemental
structures, including a body having a bottom surface, a top
surface, end surfaces, an outer surface which forms part of an
outer surface of a structure and an inner face. At least one
formation on or in at least the inner face and/or at least one of
the end faces receives and retains at least one insulating element.
The insulating element provides thermal insulation for the
structure formed from such construction blocks.
Inventors: |
Collier, Peter; (New South
Wales, AU) ; Collier, Judi; (New South Wales,
AU) |
Correspondence
Address: |
Galgano & Burke
Suite 135
300 Rabro Drive
Hauppauge
NY
11788
US
|
Family ID: |
31500394 |
Appl. No.: |
10/806592 |
Filed: |
March 23, 2004 |
Current U.S.
Class: |
52/578 ;
52/582.1 |
Current CPC
Class: |
E04B 2002/0234 20130101;
E04C 1/41 20130101; E04B 2002/0213 20130101; E04B 2/18
20130101 |
Class at
Publication: |
052/578 ;
052/582.1 |
International
Class: |
E04B 002/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 24, 2003 |
AU |
2003901351 |
Claims
1. A construction block for use in the construction of elemental
structures, the block comprising a body having a bottom surface, a
top surface, end surfaces, an outer surface which forms part of an
outer surface of a structure and an inner face; at least one
formation on or in at least the inner face and/or at least one of
the end surfaces which receive/s and retain/s at least one
insulating element; wherein, the insulating element provides
thermal insulation for a structure formed from said construction
blocks.
2. A construction block according to claim 1 wherein the at least
one insulating element comprises a prismatic body made from a
material having insulating properties; wherein the element is
secured to said block via said at least one formation.
3. A construction block according to claim 2 wherein each said
insulating element provides a thermal and water barrier to at least
one face of each said building blocks.
4. A construction block according to claim 3 wherein each formation
comprises a recess which provides a key to secure each said element
to the block.
5. A construction block according to claim 4 wherein the
construction block is formed in a mould from a cementitious
matrix.
6. A construction block according to claim 5 wherein the block
includes a formation in a surface which accommodates a
corresponding formation in said insert.
7. A construction block according to claim 6 wherein the insert
engages an inner surface of the block via said formations.
8. A construction block according to claim 7 wherein the formations
which allow engagement between a construction block and said
element are opposite gender.
9. A construction block according to claim 8 wherein each said
element engages adjacent blocks.
10. A construction block according to claim 9 wherein an insulating
element engages an end of a first construction block and an
opposing end of a second adjacent constructions block.
11. A construction block according to claim 9 wherein an insulating
element engages an inner wall of a first block and an inner wall of
an opposing block
12. A construction block according to claim 1 wherein each
insulating element is substantially the same dimension as one
dimension of one face of said block.
13. A construction block according to claim 12 wherein the
insulating element has a larger dimension than an adjacent surface
of said block.
14. A construction block according to claim 13 wherein the
insulating element and block have corresponding dovetail
formations.
15. A construction block according to claim 14 wherein each
insulating element is made from polystyrene.
16. A construction block according to claim 15 wherein an
insulating element adjacent a block sits proud of a height
dimension of said block.
17. A construction block according to claim 1 wherein the block is
manufactured in a mould from a cementitious material including
timber based aggregate.
18. A construction block according to claim 17 wherein each
polystyrene insulating element is manufactured in a mould.
19. A construction block according to claim 18 wherein the at least
one insulating element and block are integrally connected to form a
composite building element.
20. An insulating element for use in a construction block for use
in the construction of elemental structures, the block comprising:
a body having a bottom surface, a top surface, end surfaces, an
outer surface which forms part of an outer surface of a structure
and an inner face; at least one formation on or in at least the
inner face and/or at least one of the end surfaces which receive/s
and retain/s at least one insulating element; wherein, the
insulating element provides thermal insulation for a structure
formed from said construction blocks.
21. An insulating element for a construction block according to
claim 20 wherein the insulating element comprises a prismatic body
made from a material having insulating properties; wherein the
element is connected to the block via said at least one
formation.
22. An insulating element for a construction block according to
claim 21 wherein each said element provides a thermal and water
barrier to at least one face of each building block.
23. An insulating element according to claim 22 wherein each
formation in the construction block includes a recess providing a
key to secure an insert to the block.
24. An insulating element according to claim 23 wherein the element
is formed in a mould.
25. An insulating element according to claim 24 wherein the
insulating element includes a formation which accommodates a
corresponding formation in a surface in said block.
26. An insulating element according to claim 25 wherein the
insulating element engages an inner surface of the block via said
formations.
27. An insulating element according to claim 26 wherein the
formations which allow engagement between a construction block and
said element are opposite gender.
28. An insulating element according to claim 27 wherein each said
insert engages adjacent blocks.
29. An insulating element according to claim 28 wherein an insert
engages an end of a first block and an opposing end of a second
adjacent block.
30. An insulating element according to claim 28 wherein, an insert
engages an inner wall of a first block and an inner wall of an
opposing block.
31. An insulating element according to claim 1 wherein, an
insulating element has one dimension substantially the same as one
dimension of one face of said block.
32. An insulating element according to claim 31 wherein, the insert
has a larger dimension than an adjacent surface of said block.
33. An insulating element according to claim 32 wherein the insert
and block have corresponding dovetail formations.
34. An insulating element according to claim 33 wherein each
insulating element is made from polystyrene.
35. An insulating element according to claim 34 wherein an insert
adjacent a block sits proud of the height of said block.
36. An insulating element according to claim 34 wherein the
polystyrene insulating element is manufactured in a mould.
37. A structure manufactured from building blocks comprising a body
having a bottom surface, a top surface, end surfaces, an outer
surface which forms part of an outer surface of a structure and an
inner face; at least one formation on or in at least the inner face
and/or at least one of the end surfaces which receive/s and
retain/s at least one insulating element; wherein, the insulating
element provides thermal insulation for the structure formed from a
composite building element comprising said blocks and said
insulating element.
38. An insulating element for use in the thermal insulation of a
wall constructed from building blocks made from a cementitious
material; wherein, said element approximates the size of at least
one face of a building block with which the insulating element is
used, wherein, the polystyrene insert is adapted for integral
attachment with at least one said building blocks such that a
composite building element comprising said element and at least one
said blocks is formed.
39. An insulating element according to claim 38 wherein, the
insulating element is made from a material selected from insulating
materials such as a plastics material, a resin, polystyrene.
40. A composite construction element for use in the construction of
an elemental structure; wherein, the composite element comprises a
construction block and an insulating element made from a material
having insulating properties; wherein, the insulating element is
integrally attached to an inner face of the block to thereby
provide a thermal and water barrier to at least one face of each
said building blocks.
41. A composite building block including an insulating element
wherein the element provides a thermal and moisture barrier to said
block wherein, said composite is prepared in a mould and the block
is formed from a cementitious matrix; wherein said matrix is poured
in said mould while said polystyrene element is in said mould;
wherein the element and block mutually engage by opposing gender
formations to form the composite block.
42. A composite construction block including an insulating element
wherein the block is either a rectangular cube, square cube,
triangular cube, polygonal.
43. A method of construction of a composite construction block wall
having an insulating layer; wherein the method comprises the steps
of a) taking a mould capable of forming at least one building
block; b) preparing a cementitious matrix for formation of said
blocks; c) placing at least one insulating element into said mould
at a predetermined location with in the mould; d) pouring said
matrix into said mould such that the matrix engages mould surfaces
and at least one surface of said element; e) allowing said matrix
to set for a predetermined period of time; f) removing said at
least one block and said at least one element from said mould as a
composite construction element.
44. A method according to claim 43 comprising the further step of
constructing a wall from said composite construction blocks
elements thereby producing a structure having increased insulating
properties by virtue of said at least one insulating element.
45. A method of preparation of a structure formed from composite
building blocks comprising a block and an associated insulating
element connected to the block; the method comprising the steps of:
a) placing a mould of predetermined dimensions on a base surface;
b) placing at least one insulating element in said mould; c) mixing
a matrix of cementitious material and pouring said material into
said mould so that the material forms at least one block; d)
allowing said at least one insulating element to engage said matrix
so that said element forms a composite with said matrix; e)
allowing said matrix to set for a predetermined period; f) removing
said composite element and matrix from said mould.
46. A method according to claim 45 comprising the additional step
before placing said insulating element in said mould of providing
means on the element to allow the element to key into said matrix
upon setting of said matrix
47. A method according to claim 46 comprising the further step of
forming at least one gender profile in the insulating element to
enable engagement with a corresponding opposite gender profile
formed in the block when the matrix is poured against the
insulating element the block.
48. A method according to claim 47 wherein, the insulating element
is made from a material selected from a plastics material, a resin
or polystyrene.
49. An insulating element according to claim 1 wherein the element
is formed from a solid or flowable material selected from one or
more of polystyrene, foaming polyurethane, foamed rubber, foamed
concrete, vermiculite glued so as to make a board, fly ash also
glued together, low density mineral products, organic inserts
including glued low density sawdust so as to make a board, straw or
other grass like materials, rice husks glued together into a board
or matted insert.
50. A method of preparation of a structure formed from building
blocks prepared in a mould; the method comprising the steps of: a)
forming a cement of clay fired moulded block such that the finished
block includes surface formations therein on at least one surface;
b) taking at least two said blocks and placing said blocks so that
said formations on said at least one surface of two said blocks are
in spaced apart but opposing relationship to form a space formed
therebetween; c) filling said cavity between said at least two
blocks with a flowable material capable of filling said cavity; d)
allowing said flowable material to set thereby creating a composite
building element comprising said two blocks and said flowable
material.
51. A method according to claim 50 wherein the flowable material is
a foaming polyurethane or styrene or like product.
52. A method according to claim 51 wherein, the flowable material
is preferably low density and fully penetrates the cavity formed
between said blocks to form an insulating layer imparting to the
building block insulating properties and a barrier to moisture.
53. A method according to claim 52 wherein two opposing bricks are
placed with key profiles opposing each other and set to a
predetermined width.
54. A composite construction element for use in the construction of
an elemental structure; wherein, the composite element comprises
first and second spaced apart construction blocks and an insulating
element made from a material having insulating properties; wherein,
the insulating element is integrally attached to an inner face of
at least one said blocks to thereby provide a thermal and water
barrier to at least one face of each said building blocks.
55. A composite element according to claim 54 wherein, the
insulating element protrudes beyond one end of each said blocks
forming a mating tongue and is terminated short of an opposite end
of each said blocks.
56. A construction block according to claim 10 wherein an
insulating element engages an inner wall of a first block and an
inner wall of an opposing block.
57. An insulating element according to claim 29 wherein, an insert
engages an inner wall of a first block and an inner wall of an
opposing block.
Description
BACKGROUND
[0001] The present invention relates to an improved composite
building block and a method of construction using such building
blocks using a selected blend of ingredients forming a mortar
matrix and an insulating element. More particularly, the present
invention relates to an insulting element for use in the
construction of a composite building block and in wall
constructions using such building blocks. More particularly the
present invention provides a building block and a wall constructed
from such blocks having superior waterproofing, thermal and
insulating properties due to the use of the insulating element.
PRIOR ART
[0002] There are in existence a wide variety of building blocks
each tailored to suit an individual application.
[0003] Numerous construction materials have been provided in the
prior art. For example, U.S. Pat. No. 5,230,195 to Sease; U.S. Pat.
No. 5,365,714 to Potvin; U.S. Pat. No. 5,471,808 to DePieri et al.
and U.S. Pat. No. 5,505,034 to Dueck all are illustrative of such
prior art and are incorporated by reference herein. While these
units may be suitable for the particular purpose to which they
address, they would not be as suitable for the purposes of the
present invention to be described herein below.
[0004] U.S. Pat. No. 5,230,195 discloses an insulating molded
plastic building unit comprising a rectangular parallelepiped
without a rear wall. One or more alignment bosses extending
upwardly and outwardly from an upper wall of the building unit are
equidistantly spaced from a front face and a side face thereof to
cooperatively align with alignment sockets of automatically space
superimposed building units. Each building unit has vertical and
diagonal webs for structural reinforcement thereof. Cavities within
each building unit can be filled with insulating material to
enhance the insulating characteristics thereof. A plurality of the
building units are laid in courses with joints formed therebetween
with waterproof adhesive.
[0005] U.S. Pat. No. 5,365,714 discloses a wall for a rampart or
building, consisting of a plurality of building blocks, each
comprising slightly compacted sawdust or wood chips glued with
resin. The building blocks are interconnected by a number of
assembling pins and by recesses integral to the respective blocks,
so as to frictionally engage into one another. There are also
provided full length projections and corresponding grooves of the
respective blocks for the same purposes. The structure is
remarkable by the quality of the joints and by the ease and
quickness of its assembly or disassembly.
[0006] Another building block is disclosed in U.S. Pat. No.
5,471,808. The building block has a hollow body with lateral
surfaces which bear a decorative finish, a flat upper surface
having studs protruding therefrom, and a bottom opening defining
seats for accommodating the upwardly protruding studs of an
underlying block. A frog is formed in the flat upper surface for
permitting the introduction of an adhesive medium between adjacent
blocks. The block can be provided with a framework having an upper
frame and legs for interposition between adjacent blocks.
[0007] U.S. Pat. No. 5,505,034 discloses a block for forming a
retaining wall comprising a generally parallelepiped body with
front, rear, top, bottom and side surfaces and a central internal
cavity with internal walls. Integrally formed protruding knobs are
formed on the bottom surface adjacent the front surface and are
positioned for protruding into the central cavity of at least one
other block in a wall formed from the blocks.
[0008] None of the above examples of the prior art disclose a
building block manufactured in accordance with the method to be
described herein and which have improved insulating properties.
INVENTION
[0009] The present invention provides an alternative to the known
building blocks and particularly lightweight blocks having improved
insulating and moisture resistance properties. In its broadest form
the present invention comprises:
[0010] a construction block for use in the construction of
elemental structures, the block comprising a body having a bottom
surface, a top surface, end surfaces, an outer surface which forms
part of an outer surface of a structure and an inner face; at least
one formation on or in at least the inner face and/or at least one
of the end surfaces which receive/s and retain/s at least one
insulating element; wherein, the insulating element provides
thermal insulation for a structure formed from said construction
blocks.
[0011] In another broad form the present invention comprises:
[0012] a polystyrene insulating element for use in the thermal
insulation of a wall constructed from building blocks made from a
cementitious material wherein said element approximates the size of
at least one face of a building block with which the insulating
element is used, wherein the polystyrene insert is adapted for
integral attachment with at least one said building blocks such
that a composite building element comprising said element and at
least one said blocks is formed.
[0013] In another broad form the present invention comprises:
[0014] an insulating element for use in a construction block for
use in the construction of elemental structures, the block
comprising: a body having a bottom surface, a top surface, end
surfaces, an outer surface which forms part of an outer surface of
a structure and an inner face; at least one formation on or in at
least the inner face and/or at least one of the end surfaces which
receive/s and retain/s at least one insulating element; wherein,
the insulating element provides thermal insulation for a structure
formed from said construction blocks.
[0015] In another broad form the present invention comprises:
[0016] an insulating element for use in the thermal insulation of a
wall constructed from building blocks made from a cementitous
material; wherein, said element approximates the size of at least
one face of a building block with which the insulating element is
used, wherein, the polystyrene insert is adapted for integral
attachment with at least one said building blocks such that a
composite building element comprising said element and at least one
said blocks is formed.
[0017] In another broad form the present invention comprises:
[0018] a structure manufactured from building blocks comprising a
body having a bottom surface, a top surface, end surfaces, an outer
surface which forms part of an outer surface of a structure and an
inner face; at least one formation on or in at least the inner face
and/or at least one of the end surfaces which receive/s and
retain/s at least one insulating element; wherein, the insulating
element provides thermal insulation for the structure formed from a
composite building element comprising said blocks and said
insulating element.
[0019] In another broad form the present invention comprises:
[0020] a composite building block including an insulating element
wherein the element provides a thermal and moisture barrier to said
block wherein, said composite is prepared in a mould and the block
is formed from a cementitious matrix; wherein said matrix is poured
in said mould while said polystyrene element is in said mould;
wherein the element and block mutually engage by opposing gender
formations to form the composite block.
[0021] In another broad form the present invention comprises a
method of construction of a block wall having an insulating layer;
wherein the method comprise the steps of:
[0022] a) taking a mould for forming at least one building
block;
[0023] b) preparing a cementitious matrix for formation of said
blocks;
[0024] c) placing at least one element having insulating properties
in said mould;
[0025] d) pouring said matrix into said mould such that the matrix
engages mould surfaces and at least one surface of said
element;
[0026] e) allowing said matrix to set for a predetermined period of
time;
[0027] f) removing said at least one block and said at least one
element from said mould;
[0028] g) constructing a wall from said blocks and associated at
lest one element thereby producing a structure having increased
insulating properties by virtue of said at least one insert.
[0029] In another broad form the present invention comprises:
[0030] a composite building block and polystyrene element wherein
the polystyrene element provides a thermal and moisture barrier to
said block wherein said composite is prepared in a mould, the block
formed from a cementitious matrix including timber aggregate;
wherein said matrix is poured in said mould while said polystyrene
element is in said mould.
[0031] In another broad form of a method aspect the present
invention comprises:
[0032] a method of preparation of a structure formed from composite
building blocks the method comprising the steps of:
[0033] a) placing a mould of predetermined dimensions on a base
surface;
[0034] b) placing a polystyrene element in said mould;
[0035] c) mixing a matrix of cementitious material and pouring said
material into said mould so that the material forms at least one
block;
[0036] d) allowing said element to engage said matrix so that said
element forms a composite with said matrix;
[0037] e) allowing said matrix to set for a predetermined
period
[0038] f) removing said composite element and matrix from said
mould.
[0039] According to one embodiment, the method comprises the
additional step before placing said polystyrene element in said
mould of providing means on the mould to allow the element to key
into said matrix. Preferably the mould comprises walls defining an
internal space but without a base or lid so that a through passage
is provided. Preferably, the moulds are four sided but it will be
appreciated that composite blocks of alternative shapes and
configurations may be formed by alternative mould shapes.
[0040] According to a preferred embodiment, the polystyrene element
is generally elongate but includes on at least one surface,
projections which "key" into the cementitious matrix to ensure that
the insert always retains its predetermined disposition and
unwanted movement is prevented.
[0041] In another broad form of the method aspect the present
invention comprises:
[0042] a method of preparation of a structure formed from building
blocks prepared in a mould; the method comprising the steps of:
[0043] a) forming a cement of clay fired moulded block such that
the finished block includes surface formations therein on at least
one surface;
[0044] b) taking at least two said blocks and placing said blocks
so that said formations on said at least one surface of two said
blocks are in spaced apart but opposing relationship to form a
cavity therebetween;
[0045] c) filling said cavity between said at least two blocks with
a flowable material capable of filling said cavity;
[0046] d) allowing said flowable material to set thereby creating a
composite building element comprising said two blocks and said
flowable material.
[0047] According to a preferred embodiment, the flowable material
is a foaming polyurethane or styrene or like product. The foaming
product is preferably low density and fully penetrates the cavity
formed between said blocks to form an insulating layer imparting to
the building block superior insulating properties and a barrier to
moisture. Preferably two opposing bricks are placed with keys
facing each other set to a predetermined width.
[0048] a) preparing a mould;
[0049] b) placing a polystyrene element in said mould;
[0050] c) mixing a matrix of cementitious material and pouring said
material into said mould so that the material forms at least one
block;
[0051] d) allowing said element to engage said matrix so that said
element forms a composite with said matrix;
[0052] e) allowing said matrix to set for a predetermined
period;
[0053] f) removing said composite element and matrix from said
mould.
BRIEF DESCRIPTION OF DRAWINGS
[0054] The present invention will now be described in more detail
according to a preferred but non limiting embodiment and with
reference to the accompanying illustrations wherein;
[0055] FIG. 1 shows a perspective view of a polystyrene insulating
element according to one embodiment;
[0056] FIG. 2 shows a plan view of the insulating element of FIG. 1
of indefinite length.
[0057] FIG. 3 shows an abbreviated plan view of opposing insulting
elements as they would be disposed in adjacent end to end
blocks
[0058] FIG. 4 shows an elevation view of a wall section comprising
three composite blocks and styrene insulating elements
inserted.
[0059] FIG. 5 shows an end elevation of two courses of blocks
spaced apart by polystyrene elements according to a preferred
embodiment.
[0060] FIG. 6 shows a perspective view of an insulating element
insert according to an alternative embodiment
[0061] FIG. 7 shows a perspective view of an insulating element
insert according to an alternative embodiment.
[0062] FIG. 8 shows an end view of two courses of cobblestone
blocks according to an alternative embodiment and including
insulating elements.
[0063] FIGS. 9 and 10 show end views of respective mould elements
for preparing an end profile in a block according to a preferred
embodiment; and
[0064] FIGS. 11 and 12 show perspective views of different
proportioned respective mould elements for preparing an end profile
according to a preferred embodiment.
[0065] FIG. 13 shows a plan view of a polystyrene insert with
interlocking key engaging an adjacent insert.
[0066] FIGS. 14-16 shows side elevation views of blocks formed from
a mould.
[0067] FIG. 17 shows an end view of a wall section comprising a
typical rock face block, a flat face block separated by styrene
insulating element.
[0068] FIG. 18 shows a plan view of a block arrangement with hollow
core.
[0069] FIG. 19 shows an end view of the arrangement of FIG. 18.
[0070] FIG. 20 shows a plan view of a spaced apart block
arrangement with polystyrene insulating element.
[0071] FIG. 21 shows an end view of the arrangement of FIG. 20.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0072] FIG. 1 shows a perspective view of a polystyrene insulating
element profile 1 according to one embodiment. Element 1 is adapted
for use in building blocks used in the construction of structures
and preferably elemental structures such as but not limited to
walls both structural and internal non load bearing. Element 1 is
integrally fitted to a construction block during manufacture of the
block such that an integral composite is formed it may be fitted
after construction of the block and during construction of a
structure inwhcih the blocks are to be used.
[0073] Preferably, element 1 comprises a prismic body made from a
material having high insulating properties and is insertable
adjacent or in at least one said building blocks to thereby provide
a thermal and water barrier to at least one face of each said
building blocks. In a preferred embodiment, Element 1 is a
generally elongate and approximates the length of a brick which
with it will be used. For the purpose of integral engagement of
element 1 and an adjacent brick or block, element 1 may according
to one embodiment, typically comprise a generally elongate body 2
comprising a top 3 side walls 4 and 5, end walls 6 and 7 and bottom
8. Wall 4 includes dovetail formations 9, 10 and 11 and wall 5
includes formations 12, 13 and 14. Each formation provides a keying
in profile for mutual engagement between element 1 and a block not
shown. Formations 9-14 allow element 1 to embed in a cementitious
matrix formed for construction of a construction block with which
element 1 is suitable for use. Element 1 may be of definite length
as shown in FIG. 1 or indefinite length as shown in FIG. 2
depending upon job requirements. Preferably, the length of element
1 will be about the length of a building block. Element 1 further
comprises end profiles 15 and 16 formed respectively in end walls 6
and 7 and which facilitate locking engagement with a corresponding
insulating element in an adjacent (end to end) construction
block.
[0074] Formations 9-14 are preferably angled at approximately 75
degrees but it will be appreciated that this and other dimensions
of the formations may be varied according to prescription.
[0075] The formations are a predetermined width, depth and shape so
as to maximise the keying or binding effect between element 1 and
it's adjacent construction block without encroaching too deeply
into the body 2 of element 1. Each key formation 9-14 may be spaced
apart so that each is offset to its counter part on an opposite
wall. Element 1 of FIG. 1 shows formations disposed symmetrically
about longitudinal axis 17.
[0076] FIG. 3 shows a top view of opposing longitudinally disposed
styrene elements 18 and 19. Elements 18 and 19 include respective
dovetail formations 20 and 21 on one face and formations 22 and 23
on an opposing face. Elements 18 and 19 have respective opposing
ends 24 and 25. End 24 includes a recess 26 and end 25 includes a
recess 27. An insert 28 is placed intermediate elements 18 and 19
such that end 29 of insert 28 engages recess 26 and end 30 of
insert 28 engages recess 27.
[0077] FIG. 4 shows an elevation view of a wall section 31
comprising three construction blocks 32, 33 and 34. Blocks 33 and
34 receive polystyrene inserts 35 and 36. Opposing ends 37 and 38
of blocks 10 and 12 respectively, receive polystyrene insert 39
which provides a key to secure ends 37 and 38. Block 32 receives
polystyrene insert 32a.
[0078] FIG. 5 shows an end elevation of two courses of blocks 40
and 41 spaced apart by polystyrene elements 42 and 43 according to
a preferred embodiment. The arrangement shown comprises foundation
blocks 44 and 45 spaced apart by element 42 and which receive and
support a second course of blocks 46 and 47. Blocks 46 and 47 are
spaced apart by element 43. Element 42 disposed between blocks 44
and 45, sits proud of upper surfaces 48 and 49 at its upper
extremity. Preferably, according to a method aspect, blocks 45 and
47 are kept spaced apart by temporary wedge 50 whereupon mortar may
be forced into gap 51. Likewise wedge 52 separates blocks 44 and 46
allowing mortar to be introduced into gap 53.
[0079] FIG. 6 shows a perspective view of an insulating element 54
according to an alternative embodiment
[0080] FIG. 7 shows a perspective view of an insulating element 55
according to an alternative embodiment. Element 55 has a higher
height dimension that element 54. In the embodiments shown each has
only one side wall formation for engagement with a corresponding
block not shown. It will be appreciated that there could be any
number of formations in the sidewalls of a typical element or there
may be none in the case where total reliance is placed on end to
end fastening of opposing elements.
[0081] FIG. 8 shows an end view of two courses 56 and 57 of
cobblestone blocks 58, 59, 60 and 61 according to an alternative
embodiment. In the example shown, respective outer faces 62, 63, 64
and 65 of blocks 58, 59, 60 and 61 each have a radiused curve which
enhances the external appearance of the blocks. As previously
described the block arrangement shown includes insulating element
64 disposed between blocks FIGS. 9 and 10 show end views of
respective mould elements 66 and 67 for preparing an end profile in
a block according to a preferred embodiment; and
[0082] FIGS. 11 and 12 show perspective views of different
proportioned respective mould elements 66 and 67 for preparing an
end profile of an insulating element according to a preferred
embodiment.
[0083] FIG. 13 shows a plan view of an insulating element
arrangement 68 comprising mating styrene elements 69 and 70.
Element 69 separates blocks 71 and 72 and element 70 separates
blocks 73 and 74. According to the embodiment shown, element 70
includes a female gender profile 75 which engages corresponding
male gender profile tongue 76 to ensure secure interfitting between
elements 69 and 70.
[0084] According to one embodiment, element 70 preferably protrudes
past a block end forming tongue 76 but leaves a concave 75 at its
opposite end. The tongue and groove arrangement creates a
continuous unbroken styrene section from block to block so as not
to compromise the R value in perpendicular joints. The tongue and
groove arrangement ensures that each block is perfectly aligned
with it's neighbouring blocks, thus reducing the risk of human
error in laying the blocks. The tongue and groove also ensures the
perpendicular joints are of equal width and reduces the possibility
of air flow and water penetration through the perpendicular joints
as a result of poor brick laying.
[0085] According to a preferred embodiment blocks referred to
throughout this specification are preferably made from a
cementitious matrix which includes cellulose or timber aggregate.
However, it will be appreciated that other matrix mixes may be used
according to requirements.
[0086] The polystyrene elements described herein are adapted for
integral attachment with at least one said building blocks such
that a composite building element comprising polystyrene element
and at least one said blocks is formed.
[0087] According to one method aspect, construction of a block wall
having an insulating layer; comprises the following steps. First a
mould is prepared for forming building blocks. A cementitious
matrix is mixed for formation of the blocks.
[0088] At least one element having insulating properties is placed
in the mould., whereupon a cement slurry is poured into the mould
such that the matrix engages mould surfaces and at least one
surface of the element. The matrix is allowed to dry/set for a
predetermined period of time whereupon the at least one block and
at least one element is separated from said mould. A structure such
as a wall is then constructed using the composite blocks formed
from the integrally attached block and insulating element. The so
formed structure has increased insulating (and waterproofing)
properties by virtue of the at least one element.
[0089] According to one embodiment, the method comprises the
additional step before placing the polystyrene insert in said mould
of providing means on the mould to allow the element to key into
the matrix. Preferably the mould comprises walls defining an
internal space but without a base or lid so that a through passage
is provided. Preferably, the moulds are four sided but it will be
appreciated that composite blocks of alternative shapes and
configurations may be formed by alternative mould shapes.
[0090] In another embodiment, there is provided a method of
preparation of a structure formed from clay fired building blocks
prepared in a mould. A finished block includes surface formations
therein on at least one surface, such that at least two blocks are
placed so that the formations on at least one surface of the two
blocks are in spaced apart but in opposing relationship to form a
cavity therebetween. The cavity between at least two blocks with a
flowable material capable of filling the cavity. Preferably the
flowable material is a foaming polyurethane or styrene or like
product. The foaming product is preferably low density and fully
penetrates the cavity formed between said blocks to form an
insulating layer imparting to the building block superior
insulating properties and a barrier to moisture.
[0091] Preferably each block is single skin and load bearing so as
to reduce the cost and increase the speed of building and to
increase the R value (insulation). A styrene insert of
approximately 40 mm width will increase the R value of a standard
200 mm wide block made from a timber aggregate from 0.92R to
2.25R.
[0092] The polystyrene insert elements reduces all water and
moisture penetration through the block wall. They also improve the
ease, speed and accuracy of block laying (especially when using a
matrix including timber for the construction blocks), eliminate the
need for control or expansion joints and increase bond strength
between blocks. The insert elements also contribute to an increase
in overall stability of a block wall during earth tremor or quake
and decrease the chance of cracking due to movement in the footing
or slab. Further, the blocks may be nailed with all size nails and
screws without the need for pre-drilling or wall plugs.
[0093] The styrene elements are preferably disposed midway of the
width formed by two opposing blocks for the following reasons:
[0094] a) To provide sufficient thermal mass, to store energy on
the inside of the dwelling
[0095] b) Tie down rods or cyclone rods are best placed in the
centre of the block. The centre being styrene makes the drilling of
holes to house the rods easy.
[0096] c) To increase the fire rating and structural integrity of
the block wall regardless of whether the fire is on the inside of
the house or the outside. The side of the wall that is exposed to
flames will eventually lose structural integrity. Due to the
centrally mounted styrene insert heat transference is dramatically
reduced thus leaving one side of the wall structurally sound.
[0097] This composite including block and styrene insert will
dramatically improve all cement stabilised blocks and fired clay
blocks such as:
[0098] 1. Typical concrete block blend & cement stabilised mud
brick,
[0099] 2. Foamed air (or aerated concrete products),
[0100] 3. Concrete products with added low density material such as
vermiculite, fly ash, organic products such as products containing
cellulose material i.e. rice husks, sawdust and other organic
products
[0101] 4. The Timbercrete.TM. blend which is the present Applicants
previous invention.
[0102] Blocks manufactured from a cementitious matrix which
includes timber derivatives adds to the overall R (thermal rating)
value yet has better thermal mass than other products such as foam
concrete (aerated concrete). It is light weight yet strong
material. This means that the thickness of the Timbercrete section
on either side of the styrene insulating element can be wider than
conventional bricks or blocks. As a result there is a greater
surface face area which means greater bond wrench strength. Also,
the overall load bearing capacity of a wall constructed from the
blocks is increased. Due to the lighter density and greater surface
area of timber based aggregate blocks compared to solid concrete
products, are lighter and stronger are non-combustible and have low
conductivity, offering a better fire rating than most.
[0103] The composite according to the invention including the
integral insulating element is non brittle and has elastic memory
and thus is less likely to crack when subject to bending pressures.
Tests show that a 150 mm long.times.5 mm wide nail can be hammered
directly into the corner of a block without splitting or cracking
the block. In the same way any size or shape self tapping screw
will enter without the need for pre-drilling or wall plugs.
[0104] The blocks may be provided in a variety of shapes and
colours offering originality and creativity. According to a method
aspect the moulds used in the construction of the blocks may be
provided in different shapes and sizes. Setting time is longer than
the known method of timber aggregate block construction and a
reduced slump parameter is preferred. Regardless of what masonry
product is used the viscosity of the matrix is critical to an
effective product. The matrix material used must be viscous enough
to flow into all formations or wedge shaped keys of the insert
elements described above thereby creating a sound bond between
styrene insert and its adjacent masonry block. Care must be taken
to remove the mould only after prescribed setting times.
[0105] Blocks according to the invention have mortar joints which
are much thinner (preferably 5 mm) than traditional brick work
which is normally 10 to 15 mm thick.
[0106] Block corners on the ends and top (one or more sides) may be
completed with a pronounced chamfer approximately 20 mm diameter.
The chamfer on the corners and edge of the block is preferably
rounded. The top and two ends of block face may have a smooth
convex shape creating a three sided convex frame with a split face
half oval centre.
[0107] When the moulds are removed lifting it in its entirety
(without dissembling), a small slump occurs. The slump need only be
1.5-2 mm. The wet blocks subsequently rest against each other in
some places. The two blocks will join at random places and when
separated random patterns occur.
[0108] The composite block including the insulating element is non
brittle and has a limited elastic memory with a thin flexible
mortar having a strong binding quality, will produce a wall that
has many unique qualities. There is a reduced need for control and
expansion joints and reduction in the risk of cracking from
movement of footings or slabs.
[0109] Other insert element with insulating properties can be
substituted for polystyrene such as polyurethane, foamed rubber,
foamed concrete, vermiculite glued so as to make a board, fly ash
also glued together and other low density mineral products. Organic
inserts could include glued low density sawdust so as to make a
board. In similar fashion the use of straw or other grass like
materials. Also rice husks glued together into a board or matted
insert could be used as a substitute for a polyurethane insulating
element. All such products have been considered but H grade or VH
grade extruded styrene is the preferred choice for the following
reasons. H grade or VH grade styrene is stronger than most other
suggested alternatives. H grade or VH grade styrene has a higher R
value per centimeter than the other comparable materials. The cost
and ease with which extruded styrene is produced makes it
commercially viable.
[0110] The styrene insert may vary in thickness to satisfy the
particular R value that is needed to meet the required standard
that varying climatic conditions and government regulations
require. The styrene insert may be offset to one side or the other
however a centrally located insert is preferred. Cavity blocks may
be constructed but the solid light weight block is preferred
because of its greater surface face area for load bearing and bond
wrench capabilities. Also, with cavity blocks load bearing
requirements often dictate the need to fill the cavity with
concrete. This significantly increases the overall costs.
[0111] A mould with alternative mould formations may be used for
the production of alternative radii blocks according to an
alternative embodiment. Thus, depending upon the radius size of the
insert selected, this will produce blocks having a rock face with a
predetermined radius and therefore a predetermined finish. FIGS.
14,15 and 16 show side elevation views of blocks 77, 78 and 79
formed using respective mould options so that the block face has a
rock face which may be sized to leave respective distances from the
top of the blocks 77, 78 and 79 of X, Y or Z for example. The block
in FIG. 14 for instance has a rock face profile with a radius of
200 mm diameter. The block in FIG. 15 has a rock face of 180 radius
and the block of FIG. 16 has a rock face radius of 150. Thus, as
can be seen with reference to FIG. 14 the higher the radius
selected for a particular block the shorter the distance between
the rock face edge 80 and the edge 81 of the block.
[0112] FIG. 17 shows an end view of a wall section 82 comprising
typical rock face block 83 and flat face block 84 separated by
styrene insulating element 85. Block 70 is shown finished with rock
face 73. Thus according to one embodiment, a wall of rock face
blocks may be constructed with a rock face finish on an external
face and an insulating insert between opposing bricks.
[0113] FIG. 18 shows a plan view of a block arrangement 86
comprising a first block 87 and opposing block 88 defining a space
89 therebetween. Space 89 receives and retains therein an element
90 which includes hollow regions 91 and 92. Element 90 may be
disposed is in a manner which allows formation of a female gender
recess 93 and male profile part 94 which both facilitate opposite
gender engagement with end to end opposing blocks (not shown).
Hollow regions 91 and 92 cause a lower R value. For opposing blocks
of overall width 240 mm the R value will be in the order of
R1.5.
[0114] FIG. 19 shows an end view of the arrangement of FIG. 18 with
corresponding numbering.
[0115] FIG. 20 shows a plan view of a spaced apart block
arrangement with polystyrene insulating element.
[0116] Block arrangement 95 comprising a first block 96 and
opposing block 97 defining a space 98 therebetween. Space 98
receives and retains therein an element 99 which fills space 98.
Element 99 may be disposed is in a manner which allows formation of
a female gender recess 100 and male profile part 101 which both
facilitate opposite gender engagement with end to end opposing
blocks (not shown).
[0117] Since element 99 is totally solid, this will facilitate a
higher R value in the region of 2.35 depending upon the thickness
of blocks 96 and 97.
[0118] FIG. 21 shows an end view of the arrangement of FIG. 20 with
corresponding numbering.
[0119] It will be appreciated by persons skilled in the art that
numerous variations and modifications may be made to the invention
as broadly described herein without departing from the overall
spirit and scope of the invention.
* * * * *