U.S. patent application number 11/051003 was filed with the patent office on 2006-08-24 for method and implements for erecting walls including a plurality of wall components.
Invention is credited to Jean-Robert Tremblay.
Application Number | 20060185300 11/051003 |
Document ID | / |
Family ID | 36911144 |
Filed Date | 2006-08-24 |
United States Patent
Application |
20060185300 |
Kind Code |
A1 |
Tremblay; Jean-Robert |
August 24, 2006 |
Method and implements for erecting walls including a plurality of
wall components
Abstract
In combination, a first and a second wall component and a
connector for connecting the first and second wall components. The
first and second wall components are substantially elongated, each
of the first and second wall components including respective first
and second ends defining respective first and second end surfaces.
The first and second wall components have respectively first and
second substantially elongated and substantially longitudinal wall
components apertures. The connector includes a base and a first
projection extending substantially outwardly from the base, the
first projection being insertable between the first end surface of
the first wall component and the second end surface of the second
wall component. A second projection for engaging the first wall
component aperture extends substantially outwardly from the base. A
distance between the first and second projections is substantially
smaller than a distance between the first aperture and the first
end surface of the first wall component.
Inventors: |
Tremblay; Jean-Robert;
(St-Jerome, CA) |
Correspondence
Address: |
Louis Tessier
P.O. Box 54029
Town of Mount-Royal
QC
H3P 3H4
CA
|
Family ID: |
36911144 |
Appl. No.: |
11/051003 |
Filed: |
February 7, 2005 |
Current U.S.
Class: |
52/564 |
Current CPC
Class: |
E04B 2/16 20130101; E04B
2002/025 20130101; E04B 2002/0254 20130101; E04B 2002/0243
20130101 |
Class at
Publication: |
052/564 |
International
Class: |
E04B 1/02 20060101
E04B001/02 |
Claims
1) In combination with a first and a second wall component, a
connector for connecting said first and second wall components,
said combination comprising: a) first and second substantially
elongated wall components, each of said first and second wall
components including respective first and second ends defining
respective first and second end surfaces, said first and second
wall components having respectively first and second substantially
elongated and substantially longitudinal wall component apertures;
and, b) a connector including i) a base; ii) a first projection
extending substantially outwardly from said base, said first
projection being insertable between said first end surface of said
first wall component and said second end surface of said second
wall component; and, iii) a second projection for engaging said
first wall component aperture, said second projection extending
substantially outwardly from said base; c) wherein a distance
between said first and second projections is substantially smaller
than a distance between said first aperture and said first end
surface of said first wall component.
2) A combination as defined in claim 1, wherein said connector
further includes a third projection for engaging said second wall
component aperture, said third projection extending substantially
outwardly from said base, wherein a distance between said first and
third projections is substantially smaller than a distance between
said second aperture and said second end surface of said second
wall component.
3) A combination as defined in claim 2, wherein said base includes
a panel.
4) A combination as defined in claim 3, wherein said panel defines
first and second opposed support surfaces, said first support
surface contacting said first and second wall components when said
connector connects said first and second wall components.
5) A combination as defined in claim 4, further comprising a third
wall component, wherein: a) said connector is for connecting said
first and second wall components to said third wall component; and
b) said second support surface contacts said third wall component
when said connector connects said first and second wall components
to said third wall component.
6) A combination as defined in claim 5, wherein said first
projection includes a first substantially planar abutment surface
for abutting against said first wall component end surface when
said first and second wall components are positioned at a minimal
distance with respect to each other.
7) A combination as defined in claim 6, wherein said first planar
abutment surface is substantially perpendicular to said first
support surface.
8) A combination as defined in claim 7, wherein said first
projection includes a second substantially planar abutment surfaces
opposed to said first abutment surface for abutting against said
second wall component when the first and second wall components are
connected by said connector at a minimal distance with respect to
each other.
9) A combination as defined in claim 8, wherein said second planar
abutment surfaces is substantially perpendicular to said first
support surface.
10) A combination as defined in claim 9, wherein said connector
further includes a fourth projection extending substantially
outwardly from and substantially perpendicularly to said second
support surface.
11) A combination as defined in claim 10, wherein said fourth
projection is substantially collinear with said first
projection.
12) A combination as defined in claim 9, wherein said second and
third projection: a) are substantially cylindrical; b) each have a
respective longitudinal axis; c) are oriented so that their
respective longitudinal axes are substantially perpendicular to
said first support surface.
13) A combination as defined in claim 12 wherein said second and
third projections and said base define respectively first and
second connector apertures extending respectively through said
second and third projections and both extending through said
base.
14) A combination as defined in claim 13, wherein said connector
further includes fifth and sixth projections extending
substantially outwardly from said second support surface.
15) A combination as defined in claim 14, wherein: a) said fifth
and sixth projections are substantially cylindrical shells
substantially collinear respectively with said second and third
projections; and b) said fifth and sixth projections are
substantially perpendicular to said second support surface.
16) A combination as defined in claim 15, wherein said first and
second connector apertures further extend respectively through said
fifth and sixth projections.
17) A combination as defined in claim 16, wherein: a) said third
wall component is substantially elongated; b) said this wall
includes first and second ends defining respectively first and
second end surfaces of the third wall component; c) said third wall
component includes a substantially elongated and substantially
longitudinal third wall component aperture; d) said fourth, fifth
and sixth projections are insertable within said third wall
component aperture.
18) A combination as defined in claim 17, wherein said second
projection is for engaging said first wall component aperture and
said third projection is for engaging said second wall component
aperture.
19) A combination as defined in claim 18, wherein said fifth and
sixth projections are for engaging said third wall component
aperture.
20) A combination as defined in claim 5, further comprising a
spacer insertable between said connector and said first wall
component to vary a distance between said first and third wall
components.
21) A combination as defined in claim 20, wherein said spacer is
substantially annular an insertable onto said second
projection.
22) A combination as defined in claim 4, further comprising a
connector attachment extending substantially outwardly from said
connector, wherein said connector attachment is for attaching said
connector to an external structure provided in proximity to the
first and second wall components.
23) A combination as defined in claim 4, wherein: a) said panel
defines a peripheral wall connecting said first and second support
surfaces; b) said first support surface defines a depression around
said second projection, said depression extending from said second
projection to said peripheral wail.
24) A combination as defined in claim 23, wherein said depression
is for. receiving a connector attachment for attaching said
connector to an external structure provided in proximity to said
first and second wall components.
25) A combination as defined in claim 24, wherein said connector
attachment includes a connector attachment aperture for receiving
said second projection.
26) A combination as defined in claim 25, wherein said connector
attachment is substantially L-shaped.
27) A combination as defined in claim 4 further comprising indicia
provided on said peripheral wall, said indicia allowing to position
said first and second wall components at a predetermined distance
from each other.
28) A combination as defined in claim 27, wherein said indicia
include substantially rectilinear grooves engraved within said
peripheral wall.
29) A combination as defined in claim 27, wherein said indicia
include substantially rectilinear raised designs embossed over said
peripheral wall.
30) A combination as defined in claim 4, wherein said first wall
component aperture is substantially oval-shaped.
31) A combination as defined in claim 30, wherein the first and
second wall components apertures each include a substantially
uniform oval cross-section.
32) A wall, comprising: a) a plurality of wall components arranged
generally in a plurality of layers; b) a plurality of connectors
each for interconnecting a first, a second and a third wall
component from said plurality of wall components, each of said
connectors connecting said first wall component to said second wall
component so that said first and second components are at a
predetermined side-by-side spacing distance relative to each other,
said connector connecting said third wall component to both said
first and second wall components, said third wall component being
in a superposed relationship relative to said first and second wall
components with said connector provided between said third wall
component and both said first and second wall components; and c) an
interconnector connecting at least two connectors from said
plurality of connectors for substantially preventing a relative
movement between said at least two connectors.
33) A wall as defined in claim 32, wherein: a) each wall component
from said plurality of wall components is substantially elongated
and includes a respective wall component aperture extending
therethrough; and b) said interconnector extends through at least
two substantially aligned wall component apertures, each from a
respective wall component.
34) A wall as defined in claim 33, wherein: a) each connector from
said plurality of connectors defines respectively first and second
connector apertures; and b) said interconnector extends through
said first connector aperture of two substantially aligned
interconnectors.
35) A wall as defined in claim 34, wherein said first, second and
third connector aperture each include a substantially oval
cross-section.
36) A wall as defined in claim 35, wherein said wall component
apertures each define a substantially oval cross-section that is
substantially uniform within each of said wall component
apertures.
37) A wall as defined in claim 36, wherein at least a portion of
said connectors from said plurality of connectors includes an
attachment attachable thereto for attaching each connector from
said at least a portion of said connectors to an external structure
provided in proximity of said wall.
38) A wall as defined in claim 37, wherein said attachment includes
an L-shaped bracket including first and second substantially
perpendicular bracket portions, said first bracket portion being
attachable to the external structure.
39) A wall as defined in claim 34, wherein said interconnector
includes a substantially elongated rod.
40) A wall as defined in claim 39, wherein said rod is
substantially cylindrical.
41) A wall as defined in claim 34, further comprising a mortar
filling at least in part a space provided between said wall
components through said connectors.
42) A wall as defined in claim 34, further comprising a wall
foundation, said wall foundation defining a foundation aperture,
said interconnector being inserted within said foundation
aperture.
43) A wall as defined in claim 42, wherein said interconnector
engages said foundation aperture.
44) A wall as defined in claim 34, wherein each wall component from
said plurality of wall components includes a brick.
45) A wall as defined in claim 34, said wall comprising a window
aperture, said window aperture being defined by at least one window
contour component.
46) A wall as defined in claim 45, further comprising a window
connector, said window connector including: a) a base; b) a window
connector first projection extending substantially outwardly from
said base; and c) a window connector second projection extending
substantially outwardly from said base; wherein d) said at least
one window contour component defines an indentation directed
substantially away from said window, said window connector first
projection engaging said indentation and said window connector
second projection engaging a wall component aperture from a wall
component adjacent to said window.
47) A wall as defined in claim 34, wherein said interconnector
includes first and second interconnector portion, said first
interconnector portion defining a male segment at an extremity
thereof and said second interconnector portion defining a female
segment at an extremity thereof, said male segment engaging said
female segment.
48) A wall as defined in claim 47, wherein said female portion and
said male portion are substantially cylindrical, an outside
diameter of said male portion being substantially smaller than an
inside diameter of said female portion.
49) A wall as defined in claim 32, further comprising a spacer
insertable between said connector and said first wall component to
vary a distance between said first and third wall components.
50) A method for assembling a wall including a plurality of layers
of wall components, said method comprising the steps of: a)
superposing above each other the plurality of layers of wall
components; and b) securing to each other the plurality of layers
of wall components by interconnecting a plurality of wall
components through connectors, each wall component from the
plurality of wall components being included in a respective layer
from the plurality of layers of wall components.
51) A method as defined in claim 50, further comprising the step of
securing the wall to an adjacent external structure.
52) A method as defined in claim 51, wherein the wall necessitates
no bonding material to maintain structural integrity.
53) A method as defined in claim 52, further comprising the step of
inserting a bonding material between the wall components of each
layer of wall components and between wall components in adjacent
layers of wall components.
54) A method as defined in claim 53, wherein said step of inserting
a bonding material between the wall components of each layer of
wall components and between wall components in adjacent layers of
wall components is performed after said steps of: a) superposing
above each other the plurality of layers of wall components; and b)
securing to each other the plurality of layers of wall components
by interconnecting a plurality of wall components through
connectors, each wall component from the plurality of wall
components being included in a respective layer from the plurality
of layers of wall components.
55) A method as defined in claim 54, wherein said step of securing
to each other the plurality of layers of wall components includes:
a) adjusting a distance between the wall components within each
layer to a predetermined distance; and b) substantially preventing
the connectors from moving with respect to each other.
56) A method as defined in claim 55, wherein said step of securing
to each other the plurality of layers of wall components includes
leveling each layer of wall components by inserting at least one
spacer between selected wall components from adjacent layers of
wall components, the wall components being selected to obtain level
layers of wall components further to the insertion of the at least
one spacer.
57) A connector for connecting first and second substantially
elongated wall components, each wall components having respective
first and second ends defining respective first and second end
surfaces, the first and second wall components having respectively
first and second substantially elongated and substantially
longitudinal wall components apertures, said connector comprising:
a) a base; b) a first projection extending substantially outwardly
from said base, said first projection being insertable between the
first end surface of the first wall component and the second end
surface of the second wall component; and c) a second projection
for engaging the first wall component aperture, said second
projection extending substantially outwardly from said base; d)
wherein a distance between said first and second projections is
substantially smaller than a distance between the first aperture
and the first end surface of the wall component.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to the general field of
construction work, and is particularly concerned with a method and
implements to erect walls including a plurality of wall
components.
BACKGROUND OF THE INVENTION
[0002] A traditional method for erecting walls including a
plurality of wall components, such as bricks, includes laying a
first layer of wall components and subsequently adding a layer of
mortar on top of the first layer of wall components. Then, a second
layer of wall components is positioned over the first layer and
mortar is added again on top of the second layer. Usually, mortar
is also inserted between the wall components and many layers of
wall components are laid on top of each other, as described
hereinabove, and the mortar is left to dry. When the mortar is
dried, the wall has a relatively strong structural integrity.
[0003] However, the wall is typically relatively fragile while the
mortar is drying. Accordingly, typically only a limited number of
layers of wall components are laid and the mortar is left to dry
before adding further wall components on top of these layers. If
the wall is relatively tall, a relatively large amount of time is
wasted waiting for the mortar to dry.
[0004] In addition, laying the bricks requires some skill in order
for the work to be done properly. Also, labor costs associated with
brick laying are relatively high. In fact, the costs associated
with a brick wall are mainly due to labor costs.
[0005] With this traditional method, laying of walls having a
curved external surface is relatively awkward. Also, there is a
need to have a foundation on which to lay the bricks, and since the
bricks are maintained on top of each other, there is a need to have
relatively wide bricks, and therefore relatively wide foundations.
Obviously, such foundations add to the cost of erecting a
building.
[0006] The freeze and thaw cycle present in many climates can
damage the mortar and may render the wall fragile. In this case,
there is a need to rapidly repair the wall, as there is a risk that
the wall will fall apart.
[0007] In addition to this traditional technique, a few implements
have been devised to hold wall components, such as bricks, together
prior to the addition of mortar. Typically, mortar is required as
these implements are only used to position the wall elements at
relatively fixed distances therebetween. Also, since these devices
only typically connects the wall elements together, but do not
connect the wall to any other structure, the wall thereby erected
is relatively fragile if no mortar is inserted between the wall
components.
[0008] Another problem with both the use of previously provided
implements and with the traditional methods described herein above,
is that laying wall components around windows is a relatively
awkward procedure.
[0009] Against this background, there exists a need in the industry
to provide a new and improved method and implements to erect walls
including a plurality of wall components.
OBJECTS OF THE INVENTION
[0010] An object of the present invention is therefore to provide
improved method and implements to erect walls including a plurality
of wall components
SUMMARY OF THE INVENTION
[0011] In a first broad aspect, the invention provides, in
combination, a first and a second wall component and a connector
for connecting the first and second wall components. The first and
second wall components are substantially elongated, each of the
first and second wall components including respective first and
second ends defining respective first and second end surfaces. The
first and second wall components have respectively first and second
substantially elongated and substantially longitudinal wall
components apertures. The connector includes a base and a first
projection extending substantially outwardly from the base, the
first projection being insertable between the first end surface of
the first wall component and the second end surface of the second
wall component. A second projection for engaging the first wall
component aperture extends substantially outwardly from the base. A
distance between the first and second projections is substantially
smaller than a distance between the first aperture and the first
end surface of the first wall component.
[0012] Advantageously, the connector allows a relatively unskilled
user to connect together wall components at a predetermined
distance therebetween relatively easily. In addition, the connector
improves the structural rigidity of a wall including the connector.
The connector also facilitates the erection of curved walls.
[0013] In a variant, the connector further includes a third
projection for engaging the second wall component aperture. The
third projection extends substantially outwardly from the base. A
distance between the third and second projections is substantially
smaller than a distance between the second aperture and the second
end surface of the second wall component.
[0014] A non-limiting example of the wall components is a brick
including a wall component aperture extending therethrough. The
wall component aperture is of substantially oval and substantially
uniform cross-section.
[0015] In a second broad aspect, the invention provides a wall. The
wall includes a plurality of wall components arranged generally in
a plurality of layers and a plurality of connectors each for
interconnecting a first, a second and a third wall component from
the plurality of wall components. Each of the connectors connects
the first wall component to the second wall component so that the
first and second wall components are at a predetermined
side-by-side spacing distance relative to each other. The connector
connects the third wall component to both the first and second wall
components, the third wall component being in a superposed
relationship relative to the first and second wall components with
the connector provided between the third wall component and both
the first and second wall components. An interconnector connects at
least two connectors from the plurality of connectors for
substantially preventing a relative movement between the at least
two connectors.
[0016] In some embodiments of the invention, the wall has a
structural integrity large enough to be erected without the use of
mortar or any other bonding material.
[0017] In a third broad aspect, the invention provides a method for
assembling a wall including a plurality of layers of wall
components, the method comprising the steps of:
[0018] a) superposing above each other the plurality of layers of
wall components; and
[0019] b) securing to each other the plurality of layers of wall
components by interconnecting a plurality of wall components
through connectors, each wall component from the plurality of wall
components being included in a respective layer from the plurality
of layers of wall components.
[0020] In a fourth broad aspect, the invention provides a connector
for connecting first and second substantially elongated wall
components, each wall components having respective first and second
ends defining respective first and second end surfaces, the first
and second wall components having respectively first and second
substantially elongated and substantially longitudinal wall
components apertures. The connector includes: a base, a first
projection extending substantially outwardly from the base, the
first projection being insertable between the first end surface of
the first wall component and the second end surface of the second
wall component, and a second projection for engaging the first wall
component aperture, the second projection extending substantially
outwardly from the base. A distance between the first and second
projections is substantially smaller than a distance between the
first aperture and the first end surface of the wall component.
[0021] Other objects, advantages and features of the present
invention will become more apparent upon reading of the following
non-restrictive description of preferred embodiments thereof, given
by way of example only with reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In the appended drawings:
[0023] FIG. 1 is a perspective view of a partially assembled wall
including a plurality of layers of wall components, a plurality of
connectors connecting the wall components together, and an
interconnector interconnecting the layers of wall components;
[0024] FIG. 2 is a perspective exploded view of a connector of FIG.
1 into which an interconnector is inserted and connecting together
three wall components;
[0025] FIG. 3A illustrates the connection of two wall components by
the connector of FIG. 1 at a first distance therebetween;
[0026] FIG. 3B illustrates the connection of two wall components by
the connector of FIG. 1 at a second distance therebetween;
[0027] FIG. 3C illustrates the connection of two wall components by
the connector of FIG. 1 at a third distance therebetween;
[0028] FIG. 4 illustrates in a perspective exploded view the
connection of wall components to window contour components defining
a window aperture; and
[0029] FIGS. 5, 6, 7 and 8 illustrate in perspective views
alternative connectors.
[0030] FIG. 9 illustrates in perspective view the use of a spacer
in conjunction with a connector from FIG. 1.
DETAILED DESCRIPTION
[0031] FIG. 1 illustrates a wall 10 including a plurality of layers
12 of wall components 14. The wall components 14 within each layer
12 are interconnected by connectors 16. The connectors 16 further
connect wall components 14 from adjacent layers 12. Interconnectors
18 interconnect some of the connectors 16.
[0032] In some embodiments of the invention, attachments 20 allow
to attach or otherwise secure a connector 16 to an external
structure adjacent to the connector 16 to which they are attached.
In a specific embodiment of the invention shown in the drawings,
the adjacent structure is a frame of a house including wooden
boards or any other suitable structure. In this case, the
attachment 20 is secured to the wooden boards through screws, nails
or to any suitable attachment method.
[0033] In other embodiments of the invention, the frame of the
house includes any other suitable components. In yet other
embodiments of the invention, the attachment 20 is secured to any
other suitable external structure that is external and adjacent to
the wall 10.
[0034] Referring to FIGS. 1, 2, 3A, 3B and 3C, the connectors 16
keep the layers 12 away from each other at a predetermined
distance. The predetermined distance is determined in a specific
embodiment of the invention by a thickness of a base 24 of the
connector 16.
[0035] Also, the connectors 16 allow spacing from each other the
wall components 14 in a given layer 12 at a predetermined distance
from each other. In specific embodiments of the invention, the
predetermined distance is a variable distance. In other words, in
these embodiments the predetermined distance is selected by an
intended user from a range of distances.
[0036] An example of a suitable wall component 12 is a brick.
However, it is within the scope of the invention to have any other
suitable wall component.
[0037] The interconnectors 18 (not shown in FIGS. 3A, 3B and 3C)
interconnect the connectors 16 interposed between adjacent layers
12 of the wall 10. Therefore, the interconnectors 18 help in
improving the structural integrity and rigidity of the wall 10.
[0038] In some embodiments of the invention, the connectors 16, the
attachments 20 and the interconnectors 18 give a structural
rigidity to the wall 10 sufficient for the wall 10 to be erected
without the use of a binding material, such as mortar. Then, if
needed, the bonding material is added between the wall components
14 for esthetic purposes. However, in other embodiments of the
invention, mortar is inserted between the wall components 14 to
also improve the structural rigidity of the wall 10.
[0039] Referring to FIG. 1, in some embodiments of the invention,
the wall 10 is laid on a foundation 26. An example of a suitable
foundation 26 is a concrete foundation. However, any other
foundation is usable in conjunction with the invention in other
embodiments.
[0040] In a specific embodiment of the invention, as better shown
in FIG. 2, the wall components 14 take the form of substantially
elongated parallelepiped-shaped bricks including an aperture 28
extending therethrough. The aperture 28 is of a substantially oval
cross-section and the cross-section is substantially uniform
through the aperture. The aperture 28 is for receiving the
connectors 16 and the interconnectors 18 and is substantially
elongated and substantially longitudinally oriented. Each wall
component 14 has first and second ends 15 and 17 defining
respective first and second end surfaces 19 and 21.
[0041] FIG. 2 illustrates in more details one of the connectors 16.
The connector 16 includes a base 24, intercomponent projections 30
extending substantially outwardly from the base 28, the
intercomponent projections being insertable between wall components
14 from the same layer 12, and intracomponent projections 32 for
engaging the wall component apertures 28, the intracomponent
projections 32 extending substantially outwardly from the base
24.
[0042] The intercomponent projections 30 and the intracomponent
projections 32 allow connecting wall components 14 in the same
layer 12 at the variable distance therebetween. To that effect, a
distance between an intercomponent projection 30 and an adjacent
intracomponent projection 32 is substantially smaller than a
distance between an end surface 19 or 17 and the wall component
aperture 28 of each wall component 14.
[0043] In some embodiments of the invention, as shown in FIG. 2,
the connector 16 includes two intercomponent projections 30 and
four intracomponent projections 32. However, it is within the scope
of the invention to have any other suitable number of
projections.
[0044] Referring to FIG. 3A, a specific use of the connector 16 is
shown. This use will be better explained by referring to two
specific wall components 14, namely wall components 14A and
14B.
[0045] As shown in FIGS. 2 and 3A, the connector 16 includes a
panel 29 defining first and second substantially opposed support
surfaces 34 and 36. The support surface 34 contacts the wall
component 14A and 14B, while the support surface 36 contacts a wall
component 14 from a layer 12 superposed to a layer 12 including the
wall components 14A and 14B. The projections 30 and 32 extend from
the support surface 36 and are inserted within the aperture 28 of
the wall component 14 from the layer 12 superposed to the layer 12
including the wall components 14A and 14B. A peripheral wall 42
connects the support surfaces 34 and 36.
[0046] One of the intercomponent projections 30 of the connector 16
is inserted between the wall components 14A and 14B, while two
intracomponent projections 32 extending from the support surface 34
are inserted respectively within the apertures 28 of the wall
component 14A and the wall component 14B.
[0047] In a specific use, as seen on FIG. 3C, one of the
intercomponent projection 30 separates the wall components 14A and
14B at a first predetermined distance therebetween. To that effect,
the wall components 14A and 14B both contact the intercomponent
projection 16 extending from the support surface 34.
[0048] As can be seen in FIGS. 3A and 3B, two wall components 14A
and 14B within the same layer 12 do not necessarily abut the
intercomponent projection 30 that is inserted therebetween. Indeed,
if a distance between the projections 32 and the projection 30 is
sufficient, and if the apertures 28 of the wall components 14A and
14B are suitably shaped, the wall components 14A and 14B are
positionable at a variable distance therebetween.
[0049] At a maximal distance between the wall components 14A and
14B, as shown in FIG. 3A, intracomponent projections 32 contact
extremities of the apertures 28 of the wall components 14A and 14B.
In that configuration, the intercomponent projection 30 inserted
between the wall components 14A and 14B does not contact these wall
components 14A and 14B. At a minimal distance between the wall
components 14A and 14B, the situation is as described hereinabove
with respect to FIG. 3C.
[0050] At an intermediate distance shown in FIG. 3B, both the
intracomponent and intercomponent projections 32 and 30 do not
contact the extremities of the apertures 28 and the end surfaces 19
and 21 of the wall components 14A and 14B.
[0051] In some embodiments of the invention, the intracomponent
projections 32 frictionally engage the apertures 28. In this
embodiment, the connectors 16 improve the structure rigidity of the
wall 10 as opposed to a situation wherein the connectors do not
frictionally engage the apertures. In other embodiments of the
invention however, the projections 32 do not engage the apertures
28 and are simply inserted within the apertures 28.
[0052] Turning back to FIGS. 3A, 3B and 3C, the intercomponent
projections 30 include two substantially planar abutment surfaces
33 and 35 for abutting the wall components 14A and 14B when these
wall components 14A and 14B are positioned at the minimal distance
with respect to each other. The abutment surfaces 33 and 35 are
substantially perpendicular to the support surface 34.
[0053] The intracomponent projections 32 are substantially
cylindrical with a longitudinal axis substantially perpendicular to
the support surfaces 34 and 36. In a specific embodiment of the
invention, the projections 32 extending from the surface 34 are
substantially collinear with the projections 32 extending from the
support surface 36. Also, the longitudinal axis of the
intracomponent projections 32 is substantially perpendicular to the
support surfaces 34 and 36.
[0054] In some embodiments of the invention, two collinear
intracomponent projections 32 and the base 24 define a connector
aperture 40 extending therethrough. However, in alternative
embodiments of the invention, the intracomponent projections 32 do
not define apertures extending therethrough.
[0055] In some embodiments of the invention, some or all of the
connectors 16 include a respective attachment 20 or 20' extending
substantially outwardly from the connector 16. In some embodiments
of the invention, as seen in FIGS. 5, 6 and 7, an attachment 20'
extends integrally from connectors 16', which are described in
further details hereinbelow, while in other embodiments of the
invention, as shown in FIG. 2, an attachment 20 is detachable from
the connectors 16.
[0056] Depressions 44 are defined within the support surfaces 34
and 36 of the connector 16, the depressions 44 being defined around
respective intracomponent projections 32 and extending to the
peripheral wall 42. The depressions 44 are for receiving the
attachments 20. To that effect, the attachments 20 each define an
attachment aperture 46.
[0057] A specific example of an attachment 20, which is
substantially L-shaped, is shown in FIG. 2. More specifically, the
attachment 20 includes a substantially L-shaped bracket that
includes first and second substantially perpendicular bracket
portions 50 and 52. The bracket portion 50 is attachable to the
external structure while the aperture 46 is provided in the second
bracket portion 52. Therefore, the second bracket portion 52 is
received within the depression 44.
[0058] The connector 16 includes markings and indicia 54 provided
on the peripheral wall 42. The indicia 54 allow positioning of the
wall components 14A and 14B at the predetermined distance from each
other, as seen in FIGS. 3A, 3B and 3C.
[0059] In some embodiments of the invention, the indicia 54 take
the form of substantially rectilinear grooves engraved within the
peripheral wall. In other alternative embodiments of the invention,
the indicia 54 include a substantially rectilinear raised design
over the peripheral wall.
[0060] The interconnector 18 extends through the apertures 28 of
the wall components 14 and through the connector apertures 40 of
the connectors 16. Therefore, the interconnectors 18 solidify the
wall components together.
[0061] The interconnectors 18 each include a substantially
elongated rod 60. The rod 60 is substantially cylindrical. However,
it is within the scope of the invention to have rods having any
other suitable shape. The rod 60 is shaped to be substantially
snugly received within the connector apertures 40.
[0062] In some embodiments of the invention, the interconnector
includes a plurality of rods 60. Each rod 60 is included in a
respective interconnector portion. The rod 60 defines a male
segment 62 and a female segment 64. The male segment 62 is defined
at an extremity of the rod 60 and the female segment 64 is defined
at the other extremity of the rod 60. The male segment 62 of one of
the rods 60 is for engaging the female segment 64 of another of the
rods 60. To that effect, an outside diameter of the male segment 62
is substantially smaller than an inside diameter of the female
segment 64.
[0063] In some embodiments of the invention, the rod 60 defines a
rod aperture 66 extending therethrough. However, in other
embodiments of the invention, the rod 60 does not define an
aperture and is instead a solid piece of material.
[0064] Referring to FIG. 8, there is shown that in some embodiments
of the invention, a connector 16'' similar to the connector 16 is
included in the wall 10. The connector 16'' is substantially
similar to the connector 16, except that no protrusions 32 and 30
extend from the support surface 34. Therefore, the connector 16''
is positionable onto the foundation 26 of the wall 10. In some
embodiments of the invention, the base 24 of the connector 16''
does not define an aperture, and therefore the connector 16''
receives the interconnector through the intercomponent projections
32 and the interconnector abuts the base 24.
[0065] In some embodiments of the invention, the connector 16''
defines connector apertures extending therethrough and therefore
the interconnectors engage the foundation in a foundation aperture
(not shown in the drawings).
[0066] As shown in FIG. 1, in some embodiments of the invention,
the wall 10 includes a window aperture 70. The window aperture 70
is defined by at least one window contour component 77 and is for
receiving a window (not shown). The window contour components 77
are connected to adjacent wall components 14 through window
connectors 116.
[0067] One of the window connector 116 and one of the window
contour component 77 are better illustrated on FIG. 4. The window
contour component 77 is substantially elongated and includes a
substantially longitudinal indentation 79. In the specific
embodiment of the invention shown in the drawings, the window
contour component 77 is substantially parallelepiped-shaped and
includes six substantially planar walls 81a, 81b, 81c, 81d, 81e and
81f. The indentation 79 extends along substantially a whole length
of the wall 81a. However, in alternative embodiments of the
invention, the window contour component 77 is of any suitable shape
and the indentation 79 is configured in any other suitable
manner.
[0068] The window connector 160 is very similar to the connector
16, except that half of the base and two of the intracomponent
projections 32 are not present in this connector 160. Therefore, a
single intercomponent protrusion 130, generally corresponding to
the two intercomponent protrusions 30 in the connector 16, is
defined in the connector 160. The intercomponent projection 130 is
for engaging the indentation 79.
[0069] In some embodiments of the invention, it is advantageous to
have a wall 10 including half-wall components 14' in proximity to
the window contour elements 77. The half-wall components 14' are
similar to what is obtained by cutting in half one of the wall
components 14 in a plane substantially perpendicular to the
longitudinal axis of the wall components 14. The half-wall
components 14' help in preserving an offset between the wall
components 14 of adjacent layers 12.
[0070] In use, a foundation 26 of the house is first built in any
suitable manner. Then, the connectors 16'' are laid onto this
foundation 26. In alternative embodiments of the invention, the
connectors 16'' are laid into cavities defined within the
foundation. In yet other embodiments of the invention, the
foundation 26 is a concrete foundation and the connectors 16'' are
simply pushed into unsolidified concrete while erecting the
foundation 26.
[0071] Then, a layer 12 of wall components 14 is laid.
Subsequently, a layer of connectors 16 is laid onto the layer 12 of
wall components 14. A distance between the wall components 14 of
this layer 12 is adjusted at a predetermined distance as
illustrated in FIGS. 3A, 3B and 3C. Each of the connectors 16
engages a respective aperture 28 within the wall components 14 of
the first layer 12.
[0072] Afterward, a second layer 12 of wall components 14 is laid
onto the first layer. The wall components 14 of the second layer 12
are offset from the wall component 14 of the first layer and spaced
apart at the predetermined distance. This offset is such that each
of the connectors 16 on top of the first layer of wall components
16 engages two wall components 16 of the second layer 12, as
described hereinabove.
[0073] Additional layers 12 of wall components 14 are laid on top
of each other as described with respect to the first and second
layers 12 of wall components 14. When the wall has reached a height
substantially equal to a length of one of the rods 60, a rod 60 is
inserted into the connectors 16 and the apertures 28 that are
substantially aligned. Then, if required, more layers of connectors
16 and wall components 14 are added, as described hereinabove. Rods
60 are also added, as described hereinabove.
[0074] In some embodiments of the invention, the wall 10, built as
described, is left as is without the use of a bonding material.
However, in alternative embodiments of the invention, a binding
material, such as mortar, for example, is inserted in between the
wall components.
[0075] The rods 60 substantially prevent the connectors 16, and
consequently in some embodiments of the invention the wall
components 14, from moving with respect to each other. Accordingly,
a structural rigidity of the wall 10 is greatly improved. This
allows erecting the whole wall 10 without requiring the use of
mortar or any other binding material, which is only applied after a
complete assembly of the wall 10. Therefore, there is no need to
wait for the binding material to dry after laying a few layers of
wall components, which greatly diminishes a time taken to erect the
wall 10.
[0076] In addition, an increased structural rigidity of the wall 10
contributes to an improved earthquake resistance of the wall 10 and
reduces risks that the wall 10 becomes damaged through any other
cause and falls.
[0077] In specific embodiments of the invention, the attachments 20
are inserted onto connectors 16 that are aligned with the wood
planks and beams of the structure of the house, thereby allowing
attaching these connectors to this structure to further solidify
the wall 10.
[0078] Therefore, the wall 10 and its various components allow
erecting the wall 10 without using the mortar and subsequently, to
add the mortar which has mainly an esthetic function.
[0079] In some embodiments of the invention, the wall is not a
straight wall and is instead curved. This curvature is relatively
easy to achieve with the wall components 14 and the connectors 16
because of the rounded nature of the intracomponent projections 32
and of the apertures 28.
[0080] FIGS. 5 to 7 illustrate alternatives connectors 16', 16a and
16b which are similar respectively to the connectors 16, 16'' and
116, except that the attachment 20 is replaced in these connectors
16', 16a and 16b by an attachment 20' extending integrally from a
respective base 24', 24a and 24b.
[0081] FIG. 9 illustrates an alternative embodiment of the
invention including spacers 200. The spacers 200 are insertable
between a connector 16 and a wall component 14 to vary a distance
between two wall components 14 included in adjacent layers 12
connected by this connector 16. This allows an intended user to
vary a distance between layers 12, either uniformly throughout a
wall or to form a pattern with the layers 12.
[0082] In addition, the spacers 200 allow leveling the wall
components 14 within a layer 12. To that effect, a number of
spacers 200 used, which may include the use of zero spacers (the
absence of a spacer), is selected so that the wall components
within a level 12 are substantially level with respect to each
other.
[0083] As shown on FIG. 9, in a specific embodiment of the
invention, the spacer 200 is substantially annular and insertable
onto the intracomponent projections 32. In addition, the spacer 200
is shaped to be received within the depressions 44. However, in
alternative embodiments of the invention, the spacer 200 adopts any
other suitable configuration.
[0084] Although the present invention has been described
hereinabove by way of preferred embodiments thereof, it can be
modified, without departing from the spirit and nature of the
subject invention as defined in the appended claims.
* * * * *