U.S. patent application number 10/566925 was filed with the patent office on 2007-06-14 for building elements.
Invention is credited to Hugh Fisher.
Application Number | 20070130873 10/566925 |
Document ID | / |
Family ID | 27799648 |
Filed Date | 2007-06-14 |
United States Patent
Application |
20070130873 |
Kind Code |
A1 |
Fisher; Hugh |
June 14, 2007 |
Building elements
Abstract
A building element for use in construction of buildings and the
like comprises a flat body portion and first and second connecting
members. The connecting members can be attached to the body portion
following manufacture or else they can be integrally formed with
the body portion. The body portion and connecting members are
divided by fold lines in order that they may be folded into
particular shapes for use, e.g. a building block. Each end of the
body portion has a means for engaging the other end of the body
portion once the element has been folded into shape in order that
the building element shape is retained. The connecting members also
include attachment means that can attach the formed building
element to other adjacent elements. The elements are formed from
punched or cut sheet steel and/or plastics materials and are formed
into the desired shapes on site by hand.
Inventors: |
Fisher; Hugh; (Ayr,
GB) |
Correspondence
Address: |
BENESCH, FRIEDLANDER, COPLAN & ARONOFF LLP;ATTN: IP DEPARTMENT DOCKET
CLERK
2300 BP TOWER
200 PUBLIC SQUARE
CLEVELAND
OH
44114
US
|
Family ID: |
27799648 |
Appl. No.: |
10/566925 |
Filed: |
August 2, 2004 |
PCT Filed: |
August 2, 2004 |
PCT NO: |
PCT/GB04/03356 |
371 Date: |
February 5, 2007 |
Current U.S.
Class: |
52/596 ;
428/577 |
Current CPC
Class: |
E04B 2002/0215 20130101;
E04C 3/07 20130101; E04C 2003/0439 20130101; E04B 2/18 20130101;
E04B 2/8629 20130101; E04C 2003/023 20130101; Y10T 428/12229
20150115; E04C 2003/0469 20130101 |
Class at
Publication: |
052/596 ;
428/577 |
International
Class: |
E04C 2/04 20060101
E04C002/04; B21C 1/00 20060101 B21C001/00; E04B 5/04 20060101
E04B005/04 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 1, 2003 |
GB |
0318069.2 |
Claims
1. A blank for forming a building element, the blank comprising: an
elongate body portion having first and second ends and a plurality
of transverse fold lines which divide the body portion into a
plurality of panels, the panels each having first and second
longitudinal edges; one or more first tab members extending from
the first end of the body portion; and one or more first apertures
adjacent the second end of the body portion; wherein each of said
plurality of panels has at least one second tab extending from said
first longitudinal edge and a side flange portion adjacent said
second longitudinal edge, and wherein each side flange portion is
provided with at least one second aperture.
2. The blank of claim 1, wherein each side flange portion is
divided from its respective panel by a longitudinally extending
fold line which extends along the length of the body portion, and
wherein the side flange portions are adapted to be folded
substantially perpendicular to their respective panels.
3. The blank of claim 1, wherein the body portion has an end flange
portion adjacent the second end thereof, the at least one first
aperture being formed in the end flange portion.
4. The blank of claim 1, wherein the end flange portion is divided
from the body portion by one of the plurality of transverse fold
lines, and wherein the end flange portion is adapted to be folded
substantially perpendicular to the body portion.
5. The blank of claim 1, wherein one or more of the panels includes
a strengthening formation thereon.
6. The blank of claim 1, wherein one or more of the panels is
provided with a third aperture adapted to receive a reinforcing
means.
7. The blank of claim 1, wherein the building element is a building
block (12).
8. The blank of claim 1, the blank being formed from sheet
metal.
9. The blank of claim 1, the blank being formed from sheet
plastics.
10. A building block formed from the blank according to claim
1.
11. A building element comprising: a body portion having first and
second ends and comprising a plurality of integrally formed panels
adapted to define the perimeter of the building element, wherein
each panel has first and second longitudinal edges; at least one
first connecting member adapted to be attached to the panels
adjacent their first longitudinal edges; at least one second
connecting member adapted to be attached to the panels adjacent
their second longitudinal edges; and a third connected member
adapted to be attached to the body portion adjacent the first end
thereof; wherein the first and second connecting members are
provided with first and second attachment means, respectively, each
of the attachment means being adapted to attach the building
element to an adjacent building element, and wherein the third
connecting member is adapted so as to engage the second end of the
body portion.
12. The building element of claim 11, further comprising a fourth
connecting member adapted to be attached to the body portion
adjacent the second end thereof, wherein the third and fourth
connecting members are adapted so as to be mutually engagable.
13. The building element of claim 12, wherein the third and fourth
connecting members are each provided with a resilient engagement
member adapted to engage with one another.
14. The building element of claim 12, wherein the third connecting
member includes one or more apertures therein, and the fourth
connecting member includes one or more tabs projecting therefrom
for engagement with the apertures in the third connecting
member.
15. The building element of claim 11, wherein the first and second
connecting members are each formed from a single piece of material
and each is adapted to follow the perimeter of the building
element.
16. The building element of claim 11, wherein the building element
comprises a plurality of first and second connecting members
attached to each longitudinal edge of each panel.
17. The building element of claim 11, wherein each of the
connecting members is attached to the body portion using an
attachment method selected from the group comprising riveting,
gluing and crimping.
18. The building element of claim 11, wherein each of the
connecting members is provided with a plurliaty of engagement teeth
and each panel includes a plurality of cells, the teeth being
adapted to be inserted in the cells.
19. The building element of claim 18, wherein each engagement tooth
has a first engagement portion projecting in a first direction and
a second engagement portion projecting in a second, substantially
opposite, direction.
20. The building element of claim 11, wherein each of the second
connecting members includes a strengthening rib projecting
therefrom.
21. The building element of claim 11, wherein each of the first
connecting members includes a strengthening rib projecting
therefrom.
22. The building element of claim 11, wherein the first attachment
means comprises at least one tab projecting from the first
connecting member, and the second attachment means comprises at
least one aperture adapted to receive the at least one tab of an
adjacent building element.
23. The building element of claim 11, wherein the first attachment
means comprises a first fastener element and a detachable fastener
member adapted to attach to the first fastener element, and the
second attachment means comprises a second fastener element adapted
to receive a fastener member of an adjacent building element.
24. The building element of claim 11, wherein the first attachment
means comprises a detent projecting from the first connecting
member, and the second attachment means comprises a resilient catch
adapted to engage with the detent of an adjacent building
element.
25. The building element of claim 11, wherein the body portion is
formed from a single sheet of extruded cellular plastics material
having a plurality of cells therein.
26. The building element of claim 11, wherein each connecting
member is formed from sheet metal.
27. The building element of claim 11, wherein the connecting
members are formed from a plastics material.
28. The building element of claim 11, wherein at least one of the
connecting members is integrally formed with the body portion.
29. A blank for forming a building element, the blank comprising:
an elongated body portion having first and second ends and a
plurality of first apertures formed therein; and first and second
side portions integrally formed with the body portion, each side
portion being divided from the body portion along a first
longitudinally extending fold line; wherein each side portion has
at least one second longitudinal fold line which divides the side
portion into at least two sections, and wherein at least one side
portion has a plurality of tabs extending laterally therefrom.
30. The blank of claim 29, further comprising first and second end
flanges adjacent the first and second ends of the body portion,
each end flange divided from the body portion along a transverse
fold line.
31. The blank of claim 29, wherein the plurality of first apertures
are formed in two substantially parallel lines extending
longitudinally along the body portion.
32. The blank of claim 29, wherein each of the first and second
side portions has a plurality of tabs extending laterally
therefrom.
33. The blank of claim 29, wherein the building element is a door
lintel.
34. The blank of claim 29, wherein the plurality of first apertures
are formed substantially in a single line extending longitudinally
along the body portion.
35. The blank of claim 32, wherein the building element is a window
sill.
36. The blank of claim 29, wherein the blank is formed from sheet
metal.
37. The blank of claim 29, wherein the blank is formed from a
plastics material.
Description
The present invention relates to elements for the construction of
buildings and other structures.
[0001] At present, conventional materials such as bricks and cast
concrete blocks are used in order to form walls for buildings and
other structures. The normal method of building such walls is to
lay a layer of bricks or blocks and then apply a layer of wet
cement to the bricks before applying another layer of bricks or
blocks on top. This process is repeated until the wall being built
has reached the desired height. Whilst building using such
materials is not a problem in locations where these materials are
freely available, this can pose problems in areas where such items,
or the raw materials required to manufacture them, are not so
readily available. For example, the construction of accommodation
in third world countries or disaster areas can be hampered by the
lack of desired materials and building blocks.
[0002] A further disadvantage of the aforementioned conventional
materials and blocks is that they are inconvenient and costly to
transport if it is not possible to source or manufacture the
required items locally. This is a problem where speedy construction
of structures is required in remote areas by, for example, the
armed forces when seeking fortifications in a new area.
[0003] It is an object of the present invention to mitigate or
obviate one or more of the disadvantages referred to above.
[0004] According to a first aspect of the present invention there
is provided a blank for forming a building element, the blank
comprising: [0005] an elongate body portion having first and second
ends and a plurality of transverse fold lines which divide the body
portion into a plurality of panels, the panels each having first
and second longitudinal edges; [0006] one or more first tab members
extending from the first end of the body portion; and [0007] one or
more first apertures adjacent the second end of the body portion;
[0008] wherein each of said plurality of panels has at least one
second tab extending from said first longitudinal edge and a side
flange portion adjacent said second longitudinal edge, and wherein
each side flange portion is provided with at least one second
aperture.
[0009] Preferably, each side flange portion is divided from its
respective panel by a longitudinally extending fold line which
extends along the length of the body portion, the longitudinal fold
line allowing the side flange portions to be folded substantially
perpendicular to their respective panels.
[0010] Preferably, the body portion has an end flange portion
adjacent the second end thereof, the at least one first aperture
being formed in the end flange portion. Preferably, the end flange
portion is divided from the body portion by one of the plurality of
transverse fold lines, the transverse fold line allowing the end
flange portion to be folded substantially perpendicular to the body
portion.
[0011] Preferably, the ends of each side flange portion are
chamfered. Most preferably, each chamfer is at substantially 45
degrees to the longitudinal fold line.
[0012] Preferably, the body portion has three transverse fold lines
which divide the body portion into four panels. In one embodiment,
the transverse fold lines are spaced such that the first and third
panels are substantially square. In an alternative embodiment the
transverse fold lines are spaced such that each panel is
substantially square.
[0013] Preferably, each first and second tab has substantially
right-angled corners. Alternatively, each first and second tab has
rounded corners.
[0014] Preferably, each panel is stamped to provide a strengthening
formation thereon. Preferably, the formation is substantially
X-shaped. Alternatively, each panel is provided with a third
aperture for receiving a reinforcing means therethrough.
[0015] Preferably, the building element is a building block.
[0016] Preferably, the blank is formed from sheet metal, most
preferably galvanised steel. Alternatively, the blank is formed
from a plastics material.
[0017] According to a second aspect of the present invention, there
is provided a building block formed from the blank according to the
first aspect of the present invention.
[0018] According to a third aspect of the present invention, there
is provided a method of forming a building block from the blank
according to the first aspect of the invention, the method
comprising the steps of: [0019] folding each side flange portion
along the longitudinal fold line until each side flange portion
lies substantially perpendicular to its respective panel; [0020]
folding the body portion along each transverse fold line until
adjacent panels lie substantially perpendicular to one another and
the first and second ends of the body portion are adjacent one
another; and [0021] locating the at least one first tab in the
corresponding at least one first aperture and bending the at least
one tab such that the first and second ends of the body portion are
secured together.
[0022] According to a fourth aspect of the present invention, there
is provided a building element comprising: [0023] a body portion
having first and second ends and comprising a plurality of
integrally formed panels adapted to define the perimeter of the
building element, wherein each panel has first and second
longitudinal edges; [0024] at least one first connecting member
adapted to be attached to the panels adjacent their first
longitudinal edges; [0025] at least one second connecting member
adapted to be attached to the panels adjacent their second
longitudinal edges; and [0026] a third connecting member adapted to
be attached to the body portion adjacent the first end thereof;
[0027] wherein the first and second connecting members are provided
with first and second attachment means, respectively, each of the
attachment means being adapted to attach the building element to an
adjacent building element, and wherein the third connecting member
is adapted so as to engage the second end of the body portion.
[0028] Preferably, the building element further comprises a fourth
connecting member adapted to be attached to the body portion
adjacent the second end thereof, wherein the third and fourth
connecting members are adapted so as to be mutually engagable.
[0029] Preferably, the first and second connecting members are each
formed from a single piece of material and each is adapted to
follow the perimeter of the building element. Alternatively, the
building element comprises a plurality of first and second
connecting members attached to each longitudinal edge of each
panel.
[0030] Preferably, each of the connecting members is attached to
the body portion using an attachment method selected from the group
comprising riveting, gluing and crimping. Alternatively, each of
the connecting members is provided with a plurality of engagement
teeth and each panel includes a plurality of cells, the teeth being
adapted to be inserted in the cells. Preferably, each engagement
tooth has a first engagement portion projecting in a first
direction and a second engagement portion projecting in a second,
substantially opposite, direction.
[0031] Preferably, each of the second connecting members includes a
strengthening rib projecting therefrom.
[0032] Preferably, each of the first connecting members includes a
strengthening rib projecting therefrom.
[0033] In one preferred embodiment, the first attachment means
comprises at least one tab projecting from the first connecting
member, and the second attachment means comprises at least one
aperture adapted to receive the at least one tab of an adjacent
building element. In an alternative embodiment, the first
attachment means comprises a first fastener element and a
detachable fastener member adapted to attach to the first fastener
element, and the second attachment means comprises a second
fastener element adapted to receive a fastener member of an
adjacent building element. In a further alternative embodiment, the
first attachment means comprises a detent projecting from the first
connecting member, and the second attachment means comprises a
resilient catch adapted to engage with the detent of an adjacent
building element.
[0034] Preferably, the third and fourth connecting members are each
provided with a resilient engagement member adapted to engage with
one another. Alternatively, the third connecting member includes
one or more apertures therein, and the fourth connecting member
includes one or more tabs projecting therefrom for engagement with
the apertures in the third connecting member.
[0035] Preferably, the body portion is formed from a single sheet
of extruded cellular plastics material having a plurality of cells
therein. Most preferably, the plastics material is extruded
cellular polypropylene.
[0036] In one preferred embodiment, each connecting member is
formed from sheet metal. Most preferably, the sheet metal is
galvanised steel. Alternatively, the connecting members are formed
from a plastics material. In further alternative embodiment, at
least one of the connecting members is integrally formed with the
body portion.
[0037] According to a fifth aspect of the present invention, there
is provided a blank for forming a building element, the blank
comprising: [0038] an elongate body portion having first and second
ends and a plurality of first apertures formed therein; and [0039]
first and second side portions integrally formed with the body
portion, each side portion being divided from the body portion
along a first longitudinally extending fold line; [0040] wherein
each side portion has at least one second longitudinal fold line
which divides the side portion into at least two sections, and
wherein at least one side portion has a plurality of tabs extending
laterally therefrom.
[0041] Preferably, the blank further comprises first and second end
flanges adjacent the first and second ends of the body portion,
each end flange divided from the body portion along a transverse
fold line.
[0042] In a preferred embodiment, the plurality of first apertures
are formed in two substantially parallel lines extending
longitudinally along the body portion. Preferably, each of the
first and second side portions has a plurality of tabs extending
laterally therefrom. Preferably, the body portion further includes
a pair of second apertures, one of the pair located adjacent the
first end of the body portion and the other located adjacent the
second end of the body portion. Preferably, the building element is
a door lintel.
[0043] In an alternative embodiment, the plurality of apertures are
formed substantially in a single line extending longitudinally
along the body portion. Preferably, the first and second side
portions each have a pair of second longitudinal fold lines which
divide each side portion into three sections. Preferably, the
building element is a window sill.
[0044] Preferably the blank is formed from sheet metal, most
preferably galvanised steel. Alternatively, the blank is formed
from a plastics material.
[0045] Embodiments of the present invention will now be described,
by way of example only, with reference to the accompanying
drawings, in which:
[0046] FIG. 1 is a perspective view of a part pre-formed blank for
forming a building block;
[0047] FIG. 2 is a perspective view of the building block once
formed from the blank of FIG. 1;
[0048] FIG. 3 is a top view of the formed building block of FIG.
2;
[0049] FIG. 4 is a perspective view of the building block of in
FIG. 2 in use;
[0050] FIG. 5 is a cross sectional view of the building blocks of
FIG. 4 along line V-V;
[0051] FIG. 6 is a perspective view of a modified version of the
block of FIGS. 1-5;
[0052] FIG. 7 is a cross section view of a wall formed from a
number of the modified blocks shown in FIG. 6;
[0053] FIG. 8 is a side view of the part pre-formed blanks of FIG.
1 as stacked for storage.
[0054] FIG. 9 is a plan view of a blank for forming a door
lintel;
[0055] FIG. 10 is a perspective part cut-away view of the formed
door lintel;
[0056] FIG. 11 is a cross sectional view of the formed door lintel
of FIG. 10 along line XI-XI;
[0057] FIG. 12 is a perspective view of the door lintel of FIGS. 10
and 11 in use;
[0058] FIG. 13 is a plan view of a blank for forming a window
sill;
[0059] FIG. 14 is a perspective view of the window sill of FIG. 13
in use;
[0060] FIG. 15(a) is an exploded projected view of a second
embodiment of a building block;
[0061] FIG. 15(b) is a projected view of the building block of FIG.
15(a) when formed;
[0062] FIG. 15(c) is a plan view of the building block of FIGS.
15(a) and (b);
[0063] FIG. 16(a) is a projected view of a third embodiment of a
building block;
[0064] FIGS. 16(b) and (c) are vertical section detail views
through the base and top, respectively, of the building block of
FIG. 16(a);
[0065] FIGS. 16(d) and (e) are horizontal section detail views
showing alternative joint arrangements for the corners of the
building block of FIG. 16(a);
[0066] FIG. 16(f) is a vertical section detail view showing the
attachment means for attaching adjacent blocks of the type shown in
FIG. 16(a);
[0067] FIG. 17(a) is a vertical section detail view showing an
alternative attachment means for attaching adjacent blocks of the
type shown in FIG. 16(a);
[0068] FIG. 17(b) is a horizontal section detail view of a further
joint arrangement for the corners of the building block of FIG.
16(a);
[0069] FIG. 17(c) is a detail view showing stacked blanks for
forming the building blocks of FIG. 17;
[0070] FIG. 18(a) is a projected detail view of a fourth embodiment
of a building block;
[0071] FIG. 18(b) is a horizontal section detail view of a corner
joint of the fourth embodiment of building block; and
[0072] FIG. 18(c) is a vertical section detail view showing the
attachment of adjacent blocks of the fourth embodiment.
[0073] Referring to the drawings, FIG. 1 shows a blank, or body
portion, 10 from which a building element is formed. In this
instance, the building element is a building block 12. In this
embodiment, the blank 10 is either cut or punched from a sheet of
galvanised steel, although it should be understood that any other
suitable sheet metal or plastics material may be used.
[0074] The blank 10 is divided into two end panels 14,16 and two
side panels 18,20 which are integrally formed and connected along
three fold lines 22 which extend laterally across the blank 10 at
intervals along the length of the blank 10. The fold lines 22 are
formed by perforations made in the blank 10 to aid folding during
assembly, as will be explained below.
[0075] Each of the end and side panels 14-20 has an integral side
flange portion 24. Each of the side flange portions 24 is formed on
the same first longitudinal edge of the blank 10, as shown in FIG.
1. Each side flange portion 24 is connected to its respective end
or side panel 14-20 along a fold line 23. Each fold line 23 is
created by scoring or using a similar technique on the surface of
the blank 10. FIG. 1 shows the blank 10 once the side flange
portions 24 have been folded along the fold lines 23 such that they
lie substantially perpendicular to their respective end or side
panel 14-20. Each side flange portion 24 is also provided with
chamfers 26 at either end thereof to allow the blank 10 to be
formed into a cuboid shape, as will be described below.
[0076] The side flange portions 24 further include tab receiving
slots 32 formed adjacent the fold lines 23. In the illustrated
embodiment, each end panel 14,16 has one tab receiving slot 32, and
each side panel 18,20 has two tab receiving slots 32. However, it
should be appreciated that each panel 14-20 may have any number of
tab receiving slots 32, as desired.
[0077] The end and side panel 14-20 also include integrally formed
tabs 34 which lie on the second longitudinal edge of the blank 10,
opposite the side flange portions 24 formed at the first
longitudinal edge of the blank 10. The tabs 34 protrude laterally
from each panel 14,20 so as to be engagable with tab receiving
slots 32 in an adjacent block (not shown). In the illustrated
embodiment, the end panels 14,16 each have one tab 34, whereas the
side panels 18,20 each have two tabs 34. However, it should be
appreciated that each of the panels 14-20 may have any number of
tabs 34 as desired.
[0078] The first end of the blank 10 on the side panel 20 further
includes an end flange portion 38. The end flange portion 38 is
formed integrally with the side panel 20 and are connected along a
fold line 40. As with the fold lines 23 described above, the fold
line 40 is formed on the blank 10 by scoring or a similar
technique. Prior to final assembly, the end flange portion 38 is
folded along fold line 40 so that it lies substantially
perpendicular to the side panel 20, as shown in FIG. 1.
[0079] The end flange portion 38 further includes tab receiving
slots 42 formed on the end flange portion 38 adjacent the fold line
40. These tab receiving slots 42 are intended to receive tabs 44
integrally formed at the second end of the blank 10 on end panel
14. The tabs 44 protrude longitudinally from the end panel 14 and
are adapted to be engageable with the tab receiving slots 42.
Although the end panel 14 and end flange portion 38 are illustrated
as having two tabs 44 and two slots 42, respectively, it should be
appreciated that any suitable number of tabs 44 and corresponding
slots 42 may be used.
[0080] FIG. 2 illustrates a building block 12 formed from the blank
10 shown in FIG. 1. In the illustrated embodiment, the building
block 12 is formed into a substantially cuboid shape by folding
each of the panels 14-20 along the fold lines 22. Thus, the end and
side panels 14-20 each form a face of the building block 12. The
building block is secured in this form by engaging the tabs 44 of
the end panel 14 with the tab receiving slots 42 of the end flange
portion 38. The end panel 14 lies flush with the side flange
portion 38 and the tabs 44 are first manipulated so as to protrude
through tab receiving slots 42 and then bent back to fix the end
flange portion 38 and end panel 14 together. Depending on the
thickness of the sheet of material being used, the tabs can be
manipulated either by hand or else by using a suitable tool.
[0081] As best illustrated in FIG. 3, the chamfered side flange
portions 24 of the blank 10 form a base for the building block that
provides additional strength. FIG. 3 also shows the arrangement of
the slots 32 on the side flange portions 24 once the blank 10 has
been formed into the building block 12.
[0082] As illustrated in FIG. 4, the building block 12 of FIG. 2
forms one block of a wall 48 of a building or other structure. The
blanks 10 are formed into building blocks 12 which are then
assembled together. The blocks are laid on top of one another so
that the projecting tabs 34 of the lower block locate in the slots
32 of the block being laid on top. The blocks 12 may be laid
straight on top of one another, but it is preferable to lay each
layer offset from the lower layer by one half block length, as
shown in FIG. 4. When building the wall 48, fill material (not
shown) may be poured down into the hollow blocks 12 in order to
provide further strengthening and rigidity. FIG. 4 also illustrates
optional facing plates 49 which may be placed atop each block 12 in
the uppermost layer of the wall 48 once the fill material has been
poured in. The plates 49 are provided with slots (not shown) which
engage with the tabs 34 on the uppermost blocks 12.
[0083] FIG. 5 illustrates how the building blocks 12 are fixed
together in the wall 48 shown in FIG. 4. As seen in FIGS. 4 and 5,
one building block 12 is laid upon another so that the tabs 34 of
the lower block 12 engage with the slots 32 in the base of the
upper block. As discussed above, the blocks 12 may either be
stacked upon one another, or else laid in an offset fashion such
that upper block 12 is offset from the lower block 12 by one half
length. Once the blocks 12 are in the desired position and the tabs
34 are in the corresponding slots 32, the building blocks 12 are
secured together by bending the tabs 34 inwardly until they lie
flush with the side flange portions 24 of the upper block, as seen
in FIG. 5. The tabs 34 may be bent by hand or by using a tool.
[0084] FIGS. 6 and 7 show views of a modified version of the block
described above. The majority of the features of the modified block
500 are shared with the block 12 described above, and will
therefore not be described further here. The modification to the
block 500 is to introduce additional fixing slots 502,504 on each
panel 14-20 to ensure that the blocks 500 remain securely fixed
together when formed into a wall. As seen in FIG. 6, each panel
14-20 has an upper fixing slot 502 and a lower fixing slot 504. In
the illustrated embodiment, the side panels 18,20 have pairs of
upper and lower fixing slots 502,504, although they may also have
only one upper fixing slot 502 and one lower slot 504 if desired.
The upper and lower fixing slots 502,504 are each located adjacent
the top and bottom of each panel 14-20, respectively.
[0085] FIG. 7 shows a number of blocks 500 arranged in a wall. The
blocks 500 are arranged upon each other as previously described,
with the tabs 34 of the lower block 500 locating in the tab
receiving slots 32 of the upper block 500. However, with the
modified blocks 500, plastic cable ties 510 are also introduced to
hold the blocks 500 together. With the blocks arranged upon one
another, the male components of the cable ties 510 are threaded out
of the upper block 500 via the lower fixing slots 504 and into the
lower block 500 via the corresponding upper fixing slots 502 in the
lower block. The male components of the ties 510 are then finally
threaded up through the tab receiving apertures 32 in the upper
block 500 where they are fastened through the female components of
the ties in the bottom of the upper block 500. Once the ties 510
are fastened, the blocks 500 are held together in the wall.
[0086] In order to make the blocks 12 easily transportable, the
blanks 10 illustrated in FIG. 1 are able to be flat packed for easy
storage and transportation. FIG. 8 is an end view of the blanks 10
when stored for transportation. The first two blanks 10 are laid so
that their longitudinal sides provided with the tabs 34 (the second
longitudinal sides, as described above) abut one another. With the
blanks 10 laid in this manner, the pre-bent side flange portions 24
of each blank 10 face one another, with the blanks 10 each having a
substantially L-shaped profile when viewed end-on, as in FIG. 8.
Further blanks are then placed one after another on top of these
first blanks, such that the second longitudinal sides of the blanks
10 overlap in the centre of the stack and are interleaved as more
blanks are added. Eventually, the stacked blanks 10 will resemble a
truncated pyramid shape, as shown in FIG. 8, as each new blank is
laid upon the previous blank so that the side flange portions 24 of
each blank lie flush inside one another. The stack is completed
when it is no longer possible to fit a new blank in between the
opposing side flange portions of the interleaved blanks. A typical
complete stack of blanks 10 such as that shown in FIG. 8 would
comprise 225 blanks. Furthermore, a typical military air-lift
pallet would be able to hold eleven stacks, which would be enough
to make some 2,475 blocks.
[0087] Referring now to FIGS. 9-12, it may often be necessary to
include a doorway in a wall created from the building blocks 12
described above. FIGS. 9-12 illustrate a building element in the
form of a door lintel 50 that can be used in combination with a
wall of the previously described building blocks in order to form
such a doorway.
[0088] FIG. 9 shows a blank 54 from which the door lintel 50 is
formed. As with the building blocks 12, in the illustrated
embodiment the blank 54 is either cut or punched from a sheet of
galvanised steel, although any other sheet metal or suitable
plastics material may be used. The blank 54 comprises an elongate
body, or central, portion 58 and two side portions 64,66 which are
integrally formed with the body portion 58. The body portion 58 and
side portions 64,66 are connected along a pair of longitudinally
extending fold lines 68. The body portion 58 is also provided with
a pair of end flange portions 72 which are integrally formed with
the body portion 58 at respective ends thereof. Each end flange
portion 72 is connected to the body portion 58 along a lateral fold
line 70. The fold lines 68,70 may either be perforated or scored in
order to aid folding during assembly. The body portion 58 is also
provided with a plurality of slots 76,77 which, in the illustrated
embodiment, are provided in two substantially parallel lines.
[0089] Each side portion 64,66 is divided longitudinally in two by
a side portion fold line 78. The longitudinal fold lines 78 are
provided by either perforating or scoring the blank 54 in order to
aid folding during assembly. Each side portion 64,66 also includes
a plurality of tabs 80 formed integrally therewith. The tabs 80
protrude laterally from the free longitudinal edge of each side
portion 64,66 and are adapted to be engageable with the tab
receiving slots 76,77 in the body portion 58, as will be explained
below.
[0090] Although in the illustrated embodiment, the body portion 58
is shown to have eight slots in each line of slots 76,77 and the
side portions 64,66 are each shown to have eight corresponding tabs
80, it will be appreciated that any appropriate number of slots
76,77 and corresponding tags 80 may be used.
[0091] FIGS. 10 and 11 of the drawings illustrate a partial
cut-away and cross sectional view, respectively, of the door lintel
50 formed from the blank 54 of FIG. 9. As illustrated, the door
lintel 50 is formed by firstly folding end flange portions 72
downward along lateral fold lines 70 into a position whereby the
end flange portions 72 are substantially perpendicular to the body
portion 58. Next, the side portions 64,66 are folded firstly along
longitudinal fold lines 68 and then along the longitudinal fold
lines 78 into a position whereby the tabs 80 of side portions 64,66
are adjacent to tab receiving slots 76,77 of the body portion 58.
The tabs 80 can then be located in the slots 76,77 and folded out
towards the sides of the body portion 58 by hand or with a tool.
Folding the side portions 64,66 in the manner described leaves them
having a substantially V-shaped profile, as can be seen best in
FIG. 11. These V-profiles provide additional strength to the door
lintel 50 when in situ.
[0092] FIG. 12 illustrates how the door lintel 50 is attached to a
wall of building blocks 12 in order to form a doorway in the wall.
The door lintel 50 is provided with a locating slot 56 at each end
thereof and is attached to the wall by locating the lintel 50 onto
a building block 12 on either side of the doorway. The door lintel
50 is positioned on each of the pair of building blocks 12 such
that the end flange portions 72 of the lintel 50 enter the blocks
12 and lie flush with the end walls 16 of the building blocks 12.
At the same time, the tabs 34 protruding from the end walls 16 of
the blocks 12 are engaged with the locating slots 56 of the lintel
50. Once the lintel 50 is successfully located, it is secured in
place by bending the tabs 34 of the building blocks 12 so that they
are substantially flush with the body portion 58 of the lintel
50.
[0093] Referring now to FIGS. 13 and 14, it will also sometimes be
desirable to include one or more windows in a wall of the building
blocks. FIG. 13 shows a blank 84 from which a window sill 86 is
formed. The blank 84 is either cut or punched from a sheet of
galvanised steel, although any other suitable sheet metal or
plastics material may be used.
[0094] The blank 84 comprises a body portion 88 integrally formed
with first and second side portions 94,96. The body portion 88 and
side portions 94,96 are connected along a first pair of
longitudinal fold lines 98. As with the previous embodiments
described, the fold lines may be perforated or scored onto the
blank 84 to aid folding. The body portion 88 is also provided with
integral end flange portions 87 at either end thereof. The end
flange portions are connected to the body portion 88 along
respective lateral fold lines 85. The body portion 88 also includes
a plurality of tab receiving slots 89 aligned longitudinally
thereon.
[0095] The second side portion 96 is divided into three sections
96A-96C by a further two longitudinal fold lines 91,93 which run
along the second side portion 96 substantially parallel to
longitudinal fold lines 98. Again, the fold lines 91,93 are
perforated or scored on the blank 84 to aid folding during
assembly. The first side portion 94 is also divided into three
sections 94A-94C by an additional two longitudinal fold lines 95,97
which also run subtantially parallel to the longitudinal fold lines
98.
[0096] The first side portion 94 further includes tabs 99 formed
integrally with the outermost section 94C of the side portion 94.
The tabs 99 protrude laterally from the outer edge of the outermost
section 94C and are adapted to be engageable with the tab receiving
slots 89 in the body portion 88.
[0097] As with the previously described embodiments, the number of
tabs 99 and corresponding slots 89 may be greater or less than
eight, depending on the requirements of the particular
application.
[0098] FIG. 14 illustrates a window sill 86 formed from the blank
84 shown in FIG. 13. The window sill 86 is formed by firstly
folding end flange portions 87 downward along lateral fold lines 85
until they lie substantially perpendicular to the body portion
88.
[0099] Next, the first side portion 94 is folded downwards relative
to the body portion 88 along longitudinal fold line 98 until the
first side portion 94 is substantially perpendicular to the body
portion 88. The intermediate and outermost sections 94B,94C of the
first side portion 94 are then folded inwardly along fold line 95
by subtantially 90 degrees relative to the inner section 94A, and
the outermost section 94C is then folded inwardly by 90 degrees
relative to the intermediate section 94B along fold line 97. This
folding forms the first side portion 94 into a substantially
cuboidal shape, as seen best in FIG. 12, from where the tabs 99 of
the first side portion 94 can be engaged with the tab receiving
slots 89 of the body portion 88. Once engaged with the slots 89,
the tabs 99 are bent by hand or using a tool so that they lie flush
with the upper surface of the body portion 88.
[0100] Once the first side portion 94 has been folded into its
desired shape to form the load-bearing "body" of the window sill
86, the second side portion 96 can be folded to form the protective
"canopy" of the window sill 86. To create the canopy, the second
side portion 96 is folded downwards relative to the body portion 88
along longitudinal fold line 98 until it lies at substantially 90
degrees to the body portion 88. Next, the intermediate and
outermost sections 96B,96C of the second side portion 96 are bent
upwardly relative to the inner section 96A along fold line 91 until
the intermediate section 96B lies at angle of approximately 45
degrees relative to the inner section 96A, as seen best in FIG. 14.
Finally, the outermost section 96C is folded downwards relative to
the intermediate section 96B along fold line 93 until the outermost
section 96C lies in a plane substantially parallel to that of the
inner section 96A. As an option, the outermost section 96C may also
be provided with a further longitudinal fold line (not shown) which
allows a lip to be formed on the outermost section 96C such that a
rounded edge is provided. The window sill is then ready to be
attached to a wall of building blocks, such as that shown in FIG.
14.
[0101] FIGS. 15(a)-(c) show a second embodiment of a building block
in accordance with the present invention. In this second
embodiment, the block 100 has a body portion 101 and four separate
connecting members 102-108. The connecting members 102-108 are
formed from a different material to that of the body portion 101,
unlike in the first embodiment where the entire block is formed
from a single sheet of material. FIG. 15(a) shows the separate
components from which the building block 100 is formed. In this
embodiment, the connecting members 102-108 are either cut or
punched from a sheet of galvanised steel, although it should be
understood that any other suitable sheet metal or plastics material
may be used. The body portion 101 is formed from an extruded
cellular plastics sheet. An example of a suitable sheet from which
to form the body portion 101 is the extruded cellular polypropylene
sheet manufactured under the Trade Mark CORREX by Kayserberg
Plastics of Gloucester, United Kingdom. However, it should be
understood that the body portion 101 may alternatively be formed
from a variety of other suitable materials including, by way of
example, the paper-covered polymer sheet material manufactured
under the Trade Mark PARATEN by Frantschach AG of Vienna,
Austria.
[0102] The body portion 101 is divided into two end panels 114,116
and two side panels 118,120 which are integrally formed and
connected along three fold lines 122 which extend laterally across
the body portion 101 at intervals along the length thereof. The
fold lines 122 are formed by perforations made in the body 101 to
aid folding during assembly, as will be explained below. The fold
lines can also be provided in these materials by way of slots
through the material or else by reducing the thickness of the
panels at certain points to facilitate bending of the panels into
the required shape.
[0103] A lower connecting member 102 is adapted to be fixed to the
bottom longitudinal edge of the body 101. The lower connecting
member has four integral flange portions 124 which correspond to
each of the end and side panels 114,116,118,120 of the body 101.
Each of the flange portions 124 lies substantially perpendicular to
the lower connecting member 102 and is connected thereto along a
fold line 123. Each fold line 123 is created by scoring or a
similar technique on the surface of the lower connecting member
102. Each side flange portion 124 is also provided with chamfers
126 at either end thereof to allow the lower connecting member 102
to be formed into a substantially rectangular shape, as will be
described below. The side flange portions 124 further include tab
receiving slots 132 formed adjacent the fold lines 123.
[0104] An upper connecting member 104 is adapted to be fixed to the
top longitudinal edge of the body 101. The upper connecting member
104 includes integrally formed tabs 134. The tabs 134 protrude
laterally from the upper connecting member 104 so as to be
engagable with the tab receiving slots 132 in the lower connecting
member of an adjacent block when the connecting members are fixed
to the body 101.
[0105] A first end connecting member 106 is adapted to be fixed to
a first end of the body 101. The first end connecting member 106
has an integral end flange portion 138 which connects with the end
connecting member 106 along a fold line 140. As with the fold lines
123 of the lower connecting member 102, the fold line 140 is formed
on the end connecting member 106 by scoring or a similar technique.
Prior to final assembly, the end flange portion 138 is folded along
fold line 140 so that it lies substantially perpendicular to the
end connecting member 106, as shown in FIG. 15(a).
[0106] The end flange portion 138 further includes tab receiving
slots 142 formed on the end flange portion 138 adjacent the fold
line 140. These tab receiving slots 142 are intended to receive
tabs 144 integrally formed on a second end connecting member 108
adapted to be fixed to the second end of the body 101. The tabs 144
protrude longitudinally from the second end connecting member 108
and are adapted to be engageable with the tab receiving slots 142
in the first end connecting member 106. Although the first and
second end connecting members 106,108 are illustrated as having two
slots 142 and two corresponding tabs 144, respectively, it should
be appreciated that any suitable number of slots 142 or tabs 144
may be used.
[0107] The steel connecting members 102-108 and plastics body
portion 101 are fixed together prior to form the building block.
This fixing can be by any conventional means such as, for example,
riveting, adhesion or crimping. In one preferred embodiment, the
metal connecting members 102-108 can be folded over the edges of
each corresponding panel 114-120 of the body 101 and then crimped
in place.
[0108] FIG. 15(b) illustrates a building block 100 formed from the
components shown in FIG. 15(a). In the illustrated embodiment, the
building block 100 is formed into a substantially cuboid shape by
folding each of the panels 114-120 and the associated connecting
members 102-108 fixed thereto along the fold lines 122. Thus, the
end and side panels 114-120 define the outer perimeter and shape of
the block, and each form a face of the building block 100. The
building block is secured in this form by engaging the tabs 144 of
the second end connecting member 108 with the tab receiving slots
142 of the first end connecting member 106. The end panel 114 lies
flush with the side flange portion 138 of the first end connecting
member 106 and the tabs 144 are first manipulated so as to protrude
through tab receiving slots 142 and then bent back to fix the end
flange portion 138 and end panel 114 together. Depending on the
thickness of the sheet of material being used, the tabs can be
manipulated either by hand or else by using a suitable tool.
[0109] As best illustrated in FIG. 15(c), the chamfered side flange
portions 124 of the lower connecting member 102 form a base for the
building block 100 that provides additional strength. FIG. 15(c)
also shows the arrangement of the slots 132 on the side flange
portions 124 of the lower connecting member 102 once the body 101
has been formed into the building block 100.
[0110] FIGS. 16(a)-(f) show various detail views of a third
embodiment of the building block. The third embodiment of the
block, generally designated 200, is similar to the second
embodiment in that the body 201 is formed from an extruded cellular
plastics material and is divided into two end panels 214,216 and
two side panels 218,220. Panels 214-220 are integrally formed and
connected along three fold lines (not shown) which extend laterally
across the body 201 at intervals along the length thereof.
[0111] Where the third embodiment differs from the second
embodiment is that the metal connecting members have been replaced
with plastic connecting members 202-208. As best shown in FIGS.
16(b)-(f), the connecting members 202-208 are provided with
substantially U-shaped channels 222. The edge of each panel 214-220
of the body 201 has a tongue 223 extending outwardly along
substantially the length thereof. The tongues 223 are sized so as
to be held in the channels 222 of the connecting members 202-208.
This can be done by snap fit, friction fit or a similar technique.
Once the tongues 223 are fitted in the channels 222, the channels
222 can be crimped in order to strengthen the fix between the body
201 and connecting members 202-208. An adhesive may also be applied
to the joints for further strength.
[0112] Each of the lower and upper connecting members 202,204 is
provided with a number of fasteners for securing adjacent blocks
either above or below the block 200. The fasteners of this third
embodiment are snap fasteners comprising a male part 232 which is
either fixed to, or integrally formed with, the connecting members
202,204. The fasteners further comprise an elongate fastener strip
234 which is provided with a female part 236 at either end thereof.
In order to connect two blocks together, a fastener strip 234 is
snap fastened to a pair of corresponding male parts 232 in adjacent
blocks. This is best shown in FIG. 16(f), where two side panels
220,220' are connected via their respective upper and lower
connecting members 204,202 and the fastener strip 234 fastened to
the two male parts 232 of the connecting members 204,202.
[0113] As shown in FIG. 16(b), the lower connecting member 202 is
provided with a lateral stiffening web 240 which extends inwardly
from the channel 222 at substantially 90 degrees. This web 240
provides additional stiffness and rigidity to the block 200 when
fully formed and in use. The web 240 is also provided with a
locating guide 242 extending downwards therefrom at substantially
90 degrees to the web 240. This guide runs the length of the
connecting member 202 and therefore runs around the perimeter of
the block 200 when fully formed. The guide 242 ensures that the
block 200 will fit correctly on top of a lower block when in use.
The guide can be broken midway along each longitudinal side of the
block in order to allow blocks to be place on one another offset by
a half block length. This break in the guide ensures that the block
200 will accommodate the connecting member 204 forming the lateral
ends of the block below when the offset arrangement is desired.
[0114] FIGS. 16(d) and (e) show alternative arrangements for
connecting the side panel 220 and end panel 214 together to form
the block 200. In the example shown in FIG. 16(d), each of the
first and second end connecting members 206,208 is provided with a
first substantially U-shaped channel 222 for accommodating the
tongues 223 of the body panels 214,200 and a second substantially
U-shaped channel 242. The first and second channels 222,242 of the
first end connecting member 206 are formed substantially
perpendicular to one another, whereas the first and second channels
222,242 of the second end connecting member 208 are formed
substantially parallel with one another. In this way, when the
first and second end connecting members 206,208 are brought
together, the second channels 242 of each connecting member 206,208
accommodate one another, thus forming a "butcher's grip" connection
between the two connecting members 206,208. This ensures that where
the block 200 is to be filled with material for rigidity, the
connection between the two connecting members 206,208 will resist
the increased internal pressure.
[0115] The alternative connection shown in FIG. 16(e) is similar to
that shown in FIG. 16(d). However, in this alternative connection,
the tongue 223' of the end panel 214' is shorter than those
previously described. At the same time, the second end connecting
member 208' is extended so that the second channel 242' is deeper
than those previously described. The first and second end
connecting members 206,208 fit together in the same manner as
described above, but with the connection being restricted to the
same depth as the thickness of the body 201 and connecting members
206,208.
[0116] FIG. 16(f) shows a detail view of the connection between
adjacent blocks, as described above. Also shown is the web 240 and
guide 242 on the lower connecting member 202 of the upper block. It
can also be seen in FIG. 16(f) that the web includes a slot 243
located inward of the guide 242. This slot 243 is provided to
accommodate the fastener strip 234 when connecting the adjacent
blocks.
[0117] An alternative means of connecting adjacent blocks is shown
in FIGS. 17(a)-(c). The connecting members shown in these figures
have an L-shaped section, as opposed to the U-shaped section of the
connecting members shown in FIGS. 16(a)-(f). However, it should be
understood that either shape of section can be utilised for the
embodiment of connecting member shown in FIGS. 17(a)-(c).
Connecting members having the L-shaped section can be directly
adhered to the body if crimping the connecting members to the body
panels cannot easily be accomplished. There would therefore be no
need for the tongues and channels on the panels and connecting
members, respectively.
[0118] In order to fix the adjacent blocks together, as shown in
section detail in FIG. 17(a), each upper connecting member is
provided with a nib, or detent, 305 which projects inwardly towards
the centre of the formed block from the side panel 320. Each lower
connecting member 302 has a web 340 which also extends inwardly
towards the center of the formed block at substantially 90 degrees
to the lower connecting member 302. Integrally formed with the web
340, and projecting downwardly therefrom, is a resilient catch 342.
The catch 342 is adapted to engage the corresponding detent 305 of
the upper connecting member 304 such that the connecting members
302,304, and hence the adjacent blocks, are locked together.
[0119] FIG. 17(b) shows a further embodiment of the connection
between first and second end connecting members 306,308 when
forming blocks using the L-section connecting members of FIG. 17.
The connecting members 306,308 are first fixed to the side panel
320 and end panel 314, respectively, preferably by adhesion,
although alternative fixing methods may be used. Save for the use
of L-section connecting members, the connection shown in FIG. 17(b)
is substantially the same as that shown in FIG. 16(e). However, the
connection shown here differs from that of FIG. 16(e) in that the
connecting members 306,308 are each provided with a resilient catch
350. The catches 350 of each connecting member 306,308 snap
together in the same "butcher's grip" arrangement described above.
Again, this arrangement prevents the formed block from coming apart
as a result of internal pressure from fill material inside the
block.
[0120] FIG. 17(c) shows a detail view of the blanks stored ready to
form blocks. It can be seen that the lower connecting members 302
and their webs 340 ensure that the panels (only end panel 314 is
shown here) and connecting members can be flat packed ready for
transportation to a construction site.
[0121] A fourth embodiment of building block is shown in the detail
views of FIGS. 18(a)-(c). In this embodiment, the body panels are
formed as before. As can be seen from FIG. 18(a), the body 401 of
the block is formed from panels made of extruded cellular plastics
sheet, as before. Although only side panel 420 is shown in FIG.
18(a), each panel is formed the same, and includes a plurality of
cells 403 which extend across each panel. An example of the
connecting members used in this embodiment is also shown in FIG.
18(a) and is generally designated 402. Connecting members 402 such
as that shown can be used for both the upper and lower connecting
members of the block. The connecting member 402 is comb-like, in
that it has a plurality of spaced apart teeth, or prongs, 422.
Although the teeth 422 are spaced apart, they are relatively
closely packed such that a number of adjacent teeth 422 can fit
inside one cell 403 of the panels. In the example shown the teeth
422 are plate-like in shape, but it should be understood that any
suitable shape may be used. All of the teeth 422 of each connecting
member 402 are integrally formed with a strengthening rib 440,
which runs the length of the connecting member 402. The connecting
members 402 can run the length of each panel, or else they can be
shortened and only applied at the joints between panels and
adjacent blocks.
[0122] FIG. 18(b) shows in plan the connection between side panel
420 and end panel 414. As with the previously described
embodiments, first and second end connecting members 406,408 are
employed to connect the two panels 420,414 together and hence form
the closed block. Each connecting member 406,408 has a toothed
portion such as that shown in FIG. 18(a) which fixes the connecting
member 406,408 to its respective panel 420,414 via the teeth 422
entering the cells 403 of each panel 420,414. These end connecting
members 406,408 are also provided with a resilient catch 450. The
catches 450 of each connecting member 406,408 again snap together
in the same "butcher's grip" arrangement described above. As
before, this arrangement prevents the formed block from coming
apart as a result of internal pressure from fill material inside
the block.
[0123] FIG. 18(c) shows a detail section view of adjacent blocks
connected together via side panels 420,420'. Each tooth 422 of each
connecting member 402 is attached to the web 440 substantially in
the middle thereof. As a result, the web 440 divides each tooth 422
into upper and lower teeth 422a,422b. In FIG. 18(c) it can be seen
that the lower teeth 422b of the connecting member 402 slide
downwards into the cells 403 of the lower side panel 420. Once the
connecting member 402 is fixed in the lower side panel 420 (and
other connecting members are located in a similar manner at
locations around the upper perimeter of the block 400), the upper
block 400' is brought down on top of the first block 400 such that
the upper teeth 422a of the connecting member 402 enter the cells
403' of the side panel 420'. As a result, the two adjacent blocks
400,400' are now fixed together and the fix can be further
strengthened by the application of an adhesive to either or both
the upper and lower teeth 422a,422b. Where appropriate the
connecting members 402 can be modified so as to form joints at the
corners of blocks. This can be achieved by introducing
appropriately large gaps between sets of teeth and also mitres in
the web to allow the connecting members to be bent through the
required angle.
[0124] It should be understood that although the teeth illustrated
in the connecting members 402 are plate-like members, they could
also engage with the cellular panels 420 via alternative means. For
example, the teeth could be thicker, block-like members dimensioned
and spaced so as to directly engage in the cells 403 of the panel
420. The teeth could also be short, rod-like prongs which engage in
the cells 403 of the panel 420.
[0125] In addition, and as also explained elsewhere in this
specification, each of the connecting members described herein,
including those shown in FIGS. 18(a)-(c) do not necessarily have to
be formed in one continuous length to cover the entire perimeter of
the building element. Instead, the connecting members can be formed
as single members which can attach to the panels of the building
element individually. Such individual connecting members can also
be provided with strengthening webs having 45 degree cut-away ends,
so as to not interfere with adjacent connecting members if fitted
at the corners of a building element such as the blocks shown as
examples herein.
[0126] The present invention provides a number of building blocks
which are formed from sheets of metal or plastics, or a combination
of the two. The blanks for these blocks can be punched or cut from
the sheet of material and then flat packed for easy transportation
and storage. The blanks can be transported to locations where raw
building materials are in short supply and then assembled in a very
straightforward manner using only the builder's hands. If
additional supplies are available, such as rivets or adhesives for
fixing components, for example, then these may also be used to
further improve the strength of the formed building elements. With
the present invention, there is therefore no need to source scarce
materials or specialist tools to assemble buildings and structures
from the building elements according to the present invention.
[0127] It should be appreciated that the illustrated building
blocks may also be dimensioned so as to form a cube shape, in order
that half-size blocks can be used to form a particular shape of
wall or structure. As already highlighted above, the first
embodiment of building block, the door lintel and the window sill
described herein have been formed from a single sheet of galvanised
steel, but any other type of sheet metal or suitable plastics
material could be used, so long as a suitable weatherproof coating
or treatment has been applied. Alternative materials include those
used in respect of the second, third and fourth embodiments of the
blocks. Furthermore, the tabs of the first embodiment of the block,
the lintel and window sill have each been illustrated as being
substantially rectangular. However, it should be appreciated that
in order to aid engagement with the tab receiving slots, the tabs
may have rounded edges.
[0128] A further modification to the tabs would be to make them
longer so that they can not only fold flush onto a panel or flange,
but extend so that they can be folded back upon themselves for
extra strength to the join. Alternatively, the tabs could be
reduced in length to such an extent that they are merely used as
positioning means which engage the tab receiving slots but do not
protrude through the slots. In this alternative embodiment, the
securing of the building blocks in a wall would be carried out by
adding further tab receiving slots adjacent the tabs and the tab
receiving slots, and then using wire or plastic ties through the
slots to secure the building blocks together.
[0129] Although the building blocks have been illustrated as being
formed from substantially planar side and end panels, the panels
may also be stamped with a formation that adds strength to the
panels (e.g. an X-shaped stamp covering the majority of the panel)
The panels of the building blocks may also each be provided with
one or more punch-out discs. The one or more discs are aligned with
a corresponding one or more discs in the opposite panel of the
block. If reinforcement of the blocks is desired, the discs can be
punched out to allow the blocks to receive reinforcement rods which
pass through the blocks to provide additional strengthening.
[0130] The buildings and structures made from the blocks may
insulated and stablised by filling each block with a suitable
filling material, such as concrete, sand, earth, clay, gravel,
rubble or any other similar available material, depending on the
availability of such materials in then area of construction. The
blocks may also be made thermally insulated or made fire-resistant
by inserting appropriate insulating foam or fire-retardant foam
into the blocks during construction.
[0131] A further application of the blocks would be as part of a
flood prevention system. A wall of the blocks forms a first
protection layer against the flood, with a lower layer of blocks
being anchored in the ground by an appropriate means such as, for
example, scaffolding tubes. The tubes pass down through the layered
blocks into the ground. The scaffolding tubes can be set in the
blocks using cement or the like to fix the tubes in place. In
addition to the first wall of blocks, a second wall may be
constructed to the rear of the first and waterproofing may be
applied to one or both of the walls. The waterproofing may be a
sheet membrane, or any other type of waterproofing.
[0132] The building blocks can be utilised to form foundations of
buildings and other structures. For example, four building blocks
could be arranged to form a substantially square base unit, and
further blocks could be stacked in a conventional vertical manner
on top of the base unit to a suitable height. The building blocks
would be filled with cement, or another suitable material and
reinforced with typical reinforcing members such as the
aforementioned scaffolding tubes or steel reinforcement rods, for
example. The flexibility of the arrangement of the blocks means
that virtually any configuration of foundation can be achieved.
[0133] A wall constructed from the building blocks of the present
invention also provides an ideal surface for applying either an
internal or external cladding layer. The blocks can be sprayed with
a suitable treatment (e.g. for fire-proofing) and then the cladding
can be applied to the wall quickly and cheaply by simply using
self-tapping screws, or the like, that penetrate the sheet material
of the block and fix the cladding thereto.
[0134] The blocks may also be utilised to form permanent shuttering
(not shown) for the foundations of buildings or the like.
[0135] A yet further application of the building blocks is that if
the blocks are made from a sufficient thickness and/or type of
metal and/or plastics, they can be used to form a building or
structure that is resistant to attack. Thus, the blocks can be used
to quickly and simply construct military and security installations
(e.g. checkpoints). Buildings formed from the blocks would also be
less susceptible to ram-raid attacks, where an attempt is made to
drive a vehicle through the wall of a building or installation.
[0136] Each of the building elements and their separate components
described herein can be formed from either sheet metal or plastics,
using the techniques referred to above. In addition, although
certain examples given above describe the various components of the
elements as being formed separately (e.g. the body portion and
connecting members), it should be understood that these components
could be integrally formed with one another by punching, moulding
or a similar technique. These one-piece elements would be formed
with all the necessary fold lines, flutes, chamfers, cells and the
like already thereon, so that the elements can be simply folded
into shape and clipped or fixed in position.
[0137] These and other modifications and improvements may be made
to the above without departing from the scope of the present
invention.
* * * * *