AU2004237894A1

AU2004237894A1 - Interlocking block

Info

Publication number: AU2004237894A1
Application number: AU2004237894A
Authority: AU
Inventors: Tony J. Azar
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-09-30
Filing date: 2004-12-13
Publication date: 2006-06-29

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Applicant: TONY J AZAR Invention Title: INTERLOCKING BLOCK The following statement is a full description of this invention, including the best method of performing it known to us: -2

O

INTERLOCKING BLOCK The present invention is an improvement to the invention described in the applicant's earlier Australian application, namely application 2004216646 and is to be treated as a patent of addition of that application. More particularly, the present invention involves an 00improvement of the block shown in Figures 43 to 50 of Sapplication 2004216646.

The entire patent specification of application 2004216646 is hereby incorporated into this patent specification.

By way of background, the block illustrated in Figures 43 to 50 of application number 2004216646 relates to a robust concrete block for constructing a wall either above or below ground level. The block includes a front panel, a rear panel, and at least one web connecting the front and rear panels. The front and rear panels are rectangular in shape. The webs connecting the front and rear panels have top and bottom surfaces that are coextensive with top and bottom surfaces of the panels and thereby form a top and bottom surface of the block. The top surface of the block is provided with a shallow rectangular ridge that extends in a longitudinal direction along the block. The bottom surface of the block is provided with a shallow rectangular channel. In addition, the block has right and left profiled ends surfaces, wherein the right front edge surface and the left rear edge surface each have a convex protrusion, and the right rear edge surface and the left front edge surface each have a concave recess. The convex protrusion and concave recess are complimentary in shape and allow the blocks to be interfit end-to-end.

An object of the present invention is to provide additional benefits and advantages to the block described in application 2004216646.

According to the present invention there is H:\Pcabral\Keep\speci\p55075.doc 13/12/04 3 O provided a construction block for use in constructing o walls, said block including a front panel, a rear panel, Sand at least one web connecting said front and rear Spanels, each of said front and rear panels being rectangular and having a top edge surface, a bottom edge surface, and right and left edge surfaces, said at least one web having top and bottom surfaces co-extensive with 00 the top and bottom surfaces of said front and read panels Sthereby to define a top surface of said block, and a bottom surface of said block, said top surface of said block being provided with one or more than one raised c( ridges in a length wise direction, the raised ridges being flanked by longitudinally extending outer support surfaces, the bottom surface of said block having one or more than one shallow channel that can receive the ridges on an upper surface of a lower brick when one of said bricks are placed one on top of the other, the channels being formed therein along its length, flanked by longitudinally extending flat outer foot portions corresponding in width to said outer support surfaces; and wherein any one or more of the following portions of the block is in the form of a bevelled surface: a junction of the top surface and the front panel; a junction of the top surface and the rear panel; o an outer right corner of the front panel; an outer right corner of the rear panel; an outer left corner of the front panel; and an outer left corner of the rear panel.

It is preferred that said front and rear panels are thickened toward the interior of said block at their right and left ends.

It is preferred that said first profile be a concave vertical groove, and said second profile be a convex vertical ridge.

It is preferred that said concave vertical groove be formed on the inner corner of said edge surface.

It is preferred that said vertical ridge be formed H:\Pcabral\Keep\speci\p55075.doc 13/12/04 -4c on the inner corner of said edge surface.

o It is also preferred that the construction block also include two of said webs and a hollow core is Sprovided between the webs.

It is preferred that the lower surface of the webs include cut outs that can accommodate reinforcing material spanning between two or more of the blocks.

00 0According to the present invention there is also provided a corner block for form the corner of a wall structure. The corner block including a front panel, a rear panel, and at least one web connecting said front and rear panels, each of said front and read panels being rectangular and having a top edge surface, a bottom edge surface, and right and left edge surfaces, said at least one web having top and bottom surfaces co-extensive with the top and bottom surfaces of said front and rear panels thereby define top and bottom surfaces of said block, said top surface of said block being provided with one or more than one raised ridges extending in a length wise direction, the raised ridges being flanked by longitudinally extending outer support surfaces, the bottom surface of said block having one or more than one shallow channel that can receive the ridges on an upper surface of a lower brick when one of said bricks are placed one on top of the other, the channels being flanked by longitudinally extending flat outer foot portions corresponding in width to said outer support surfaces; and wherein any one or more of the following portions of the block is in the form of bevelled surface: 0 a junction of the top surface of the block and the front panel; a junction of the top surface of the block and the rear panel; 0 an outer right corner of the front panel; 0 an outer right corner of the rear panel; an outer left corner of the front panel; and 0 an outer left corner of the rear panel, H:\Pcabral\Keep\speci\p55075.doc 13/12/04 O and wherein the front and/or rear panels include a o vertical groove that can receive a complementary ridge protruding from the end of another block such that said M other block can be located and interfit in a lateral position with the corner block to form a corner structure.

It is preferred that said other block for interfitting with the corner block be the construction 00 block described above.

CWith respect to the corner block, it is preferred that the a right edge surface of said front and rear panels have first and second profiles respectively, and the left end of the block includes an end web interconnecting the front and rear panels, and the first and second profiles are complementary to said first and second profiles of said construction blocks to permit the corner block to interfit end-to-end with said construction block.

It is also preferred that the left edge surface of the said front and rear panels of the corner block have first and second profiles respectively and a end web interconnecting the front and rear panels at the right end of the block, and the first and second profiles are complementary to the first and second profiles of said construction block to permit the corner block to interfit end-to-end with said construction block.

Brief Description of the Drawings A preferred embodiment of the present invention will now be described with reference to the accompanying drawings which illustrate a set of blocks for forming a wall structure. The drawings may be described as follows: Figure 1 illustrates an outline of a stretcher block used for forming a wall; Figures 2 and 3 illustrate an outline of right and left corner blocks respectively for forming a wall structure; Figures 4 and 5 illustrate an outline of full and half H:\Pcabral\Keep\speci\p55075.doc 13/12/04 6 O sash blocks respectively for forming a wall structure; o Figure 6 illustrates an outline of a double corner sash block which can be used for forming either one or M both of a left or right corner; Figure 7 illustrates how the blocks shown in Figures 1 to 6 can be fitted together to form a wall.

Figures 8A to 8C illustrate three alternative end 00views of the stretch block shown in Figure 1; M Figure 9 is a close up vertical cross-sectional view showing a bevelled surface of a block according to any one of the Figures 1 to 8; Figure 10 is a close up horizontal cross-sectional view of two blocks as showing in any one of the Figures 1 to 8 placed end-to-end; and Figures 11A to 11C illustrate a conventional brick wall structure including the stretcher block, and the left and right corner blocks shown in Figures 1 to 3.

Detailed Description Figures 1 to 10 illustrate a preferred set of blocks that may be utilized in a construction of a brick wall. Figure 7 provides an overview of the different types of blocks included in the preferred set of blocks.

The set of blocks includes: a stretcher block 10, a right corner block 11, a left corner block 12, a full sash block 13, a half sash block 14, and a double corner block The blocks have a number of features in common and the same reference numerals have been used throughout the drawings to identify the same or substantially similar features on each type of block.

The blocks include rectangular front 21 and rear 22 panels that are interconnected by at least one rectangular shaped web 23. The front and rear panels 21, 22, and the web 23 interconnecting the front and rear panels 21, 22 also provide top and bottomsurfaces to the block.

The left 24 and right 25 outer edges of the front H:\Pcabral\Keep\speci\p55075.doc 13/12/04 7 O 21 and rear 22 panels of the blocks include a bevelled Ssurface 26 that facilitates easier manufacture of the Sblocks from moulds. Another benefit provided by the Sbevelled surfaces is that when the blocks are placed to end, the bevelled surfaces provide the false appearance of a mortar join between the blocks.

Figure 10 illustrates a close up view of a 00 horizontal cross-section of two blocks placed end-to-end.

SThe bevelled surface 26 on each block shown in Figure is approximately one eighth of an inch or greater in size.

In addition, Figure 9 illustrates a close up view c( of cross-section showing the junction between the top surface of a front 21 or rear 22 panel of a block and a further block placed on the top thereof. The junctions between the front and rear panels 21, 22 and the top surface includes a bevelled surface 26 that is approximately one quarter of an inch or greater in size.

Referring back to Figure 1, the stretch block includes two web members 23 that span between the front and rear panels 21 and 22 at locations spaced from the ends of each block. The left edge of the front panel 21 includes a shaped profile in the form of a concave recess 27 and the right edge of the front panel 26 includes a complimentary shaped convex ridge 28. The left and right edges of the rear panel also include similar profiles with a concave recess 30 and a convex ridge 29 at each respectively. The profiles at the edges of the stretcher block 10 allows the stretch blocks 10 to be placed end-toend to form a row.

It will be observed that the overall length of the front and rear panels is substantially the same and slightly offset. At each end, however, a flat portion 31 adjacent the concave interfit element will be aligned with the outer edge of the convex interfit element on the opposite front 21, or rear panel 22. Therefore, when the blocks are laid in a course, the course will run straight.

Figure 2 illustrates a block called a right corner H:\Pcabral\Keep\speci\p55075.doc 13/12/04 8 o block 11 which is similar to the stretch block 10 shown in Sthe Figure 1 and includes two central web members 23 interconnecting the front and rear panels 21, 22 that Sdefine a central core 32. However, the right corner block 11 also includes an additional web 33 located at an end of the block that forms an end wall and defines a second central core 34. Furthermore, a concave channel 35 is 0provided in the front panel 21 at a location that is M spaced from the end of the block by a distance approximately equal to the width of the stretcher block The wall structure shown at the top left corner of the Figure 7 shows that in use, the concave channel is designed to complement and receive the convex ridge 29 projecting from the left edge of a rear panel 22 of another block placed laterally thereto and to the right hand side of the right corner block 11.

Figure 3 illustrates a left corner block 12 which is similar to the right corner block 11 shown in Figure 2 save for a concave channel 36 formed in the rear panel 22 which, as can be seen in Figure 7, is design to compliment and receive the convex ridge 28 projecting from the front right panel 21 of the another block when placed laterally of the left corner block.

Figure 4 illustrates a full sash block 13 that includes a web 33 at one end of the block but unlike the left and right corner blocks 11 and 12 does not include a concave channel in the front or rear panels 21 and 22. As can been in Figure 7, the block is intended to form the end block of a wall structure.

Figure 5 illustrates a half sash block 14 which is effectively half the size of a full sash block 13 shown in the Figure 4. The half sash block 14 has essentially a square shape with a front and rear panels 21, 22 and two webs at either end of the block 23 and 33. The web 23 includes in a convex ridge and concave recess which compliment the concave recess 37 and convex ridge 38. As can be seen in the Figure 7, in use, the half sash block H:\Pcabral\Keep\speci\p55075.doc 13/12/04 9 14 can be butted up against the end of the stretcher 11 or o corner block 12, 13 to form the end of a wall.

Figure 6 illustrates a double corner block Swhich has a single web 23 connecting the front and rear panels 21, 22 and two further webs 33, one at each end of the block 15. The front and rear panels 21, 22 also have a concave channel 39 that are shaped to compliment the 00convex ridges projecting from the edge of the other blocks M shown in the drawings. The concave channels 39 are spaced from the ends of the blocks so that when one block placed laterally to another block, the end of the double corner blocks is aligned with the front panel 21 of an adjacent block placed laterally thereto.

The internal webs 23 of each of the blocks shown in the drawings include one or more than one channel in the bottom surface thereof which according to the embodiment shown in Figures 8B and 8C is in the form of a semi-circular cut-outs 40. The cut outs 40 are designed to receive elongated re-enforcement bars that extend within a course of blocks and, thereby add strength a wall structure. In addition, depending on the end use of the wall structure, concrete may also be poured inside the central cores 32, 34 of the blocks. The concrete will add additional stretch and help secure the re-enforcement bars in position. Depending of the size of the cut outs 40 and re-enforcement bars the cut outs 40 will also enable concrete to communicate between the central cores 32, 34 and thereby enable a continuous concrete grid to be formed within a wall structure.

Figure 8A illustrates an embodiment in which two cut outs 40 are formed in the bottom surface of each web 23.

In order to facilitate the blocks to be stacked one on top of the other in a stable fashion, the upper surface of each block includes two raised ridges 41 that extend substantially along the length of the blocks. The bottom surface of each block also includes two grooves 42 H:\Pcabral\Keep\speci\p55075.doc 13/12/04 Sthat are profiled to interfit with the raised ridges 41.

o The embodiments shown in Figures 8B and 8C are examples in which the grooves 42 are formed independently of the cut Souts 40 for the re-enforcement bar. The embodiment shown in Figure 8A is an example in which the grooves 42 forms part of the cut outs 40 for the re-enforcement bar.

The raised ridges 41 on the upper surface of each 00 0block may have any height but preferably the height ranges Sfrom approximately inch to 1 inch. Located on the outside of each ridge is a flat portion 43 that has a width that preferably ranges between t to 1i inches. A corresponding foot portion 44 also provided on the bottom surface of the blocks.

Figures 11A to 11C illustrate a series of courses of blocks laid one on top of the other. The brick wall is an L-shape with one limb of the wall extending into the page as indicated by the blocks shown in Figure 11B which illustrate a bottom course of blocks. Left and right corner blocks 11 and 12 are placed one on top of the other in an alternating sequence to form the corner of the wall.

A person skilled in the art of the present invention will appreciate that many modifications and variations may be made to the preferred embodiment described above without departing from the spirit and scope of the present invention.

H:\Pcabral\Keep\speci\p55075.doc 13/12/04

Claims

1. A construction block for use in constructing Swalls, said block including a front panel, a rear panel, and at least one web connecting said front and rear panels, each of said front and rear panels being rectangular and having a top edge surface, a bottom edge 0surface, and right and left edge surfaces, said at least Sone web having top and bottom surfaces co-extensive with the top and bottom surfaces of said front and rear panels and thereby define top and bottom surfaces of said block, said top surface of said block being provided with one or more than one raised ridges extending in a length wise direction, the raised ridges being flanked by longitudinally extending outer support surfaces, the bottom surface of said block having one or more than one shallow channel that can receive the ridges on an upper surface of a lower brick when one of said bricks are placed one on top of the other, the channels being flanked by longitudinally extending flat outer foot portions corresponding in width to said outer support surfaces; the right and left edge surfaces of said front and rear panels being profiled to inter-fit with one another, whereby the right front edge surface and the left rear edge surface each have a first profile, and the left front edge surface and the right rear edge surface each have a second profile, the first and second profiles being complementary to permit blocks to inter-fit end-to-end, and wherein any one or more of the following portions of the block is in the form of bevelled surface: a junction of the top surface of the block and the front panel; a junction of the top surface of the block and the rear panel; 0 an outer right corner of the front panel; an outer right corner of the rear panel; an outer left corner of the front panel; and H:\Pcabral\Keep\speci\p55075.doc 13/12/04 -12- S an outer left corner of the rear panel.

2. The block according to claim i, wherein said front and rear panels are thickened toward the interior of said block at their right and left ends.

3. The block according to claim 2, wherein said first 00 profile is a concave vertical groove, and said second profile is a convex vertical ridge. (Ni

4. The block according to claim 3, wherein said concave vertical groove is formed on the inner corner of said edge surface.

5. The block according to claim 4, wherein said vertical ridge is formed on the inner corner of said edge surface.

6. The block according to any one of claims 1 to including two of said webs and a hollow core is provided between the webs.

7. The block according to any one of claims 1 to 6, wherein the lower surface of the webs includes cut outs that can accommodate reinforcing material spanning between two or more of the blocks.

8. A corner block for use in constructing walls, said block including a front panel, a rear panel, and at least one web connecting said front and rear panels, each of said front and read panels being rectangular and having a top edge surface, a bottom edge surface, and right and left edge surfaces, said at least one web having top and bottom surfaces co-extensive with the top and bottom surfaces of said front and rear panels thereby define top and bottom surfaces of said block, said top surface of said block being provided with one or more than one raised H:\Pcabral\Keep\speci\p55075.doc 13/12/04 -13- ridges extending in a length wise direction, the raised o ridges being flanked by longitudinally extending outer support surfaces, the bottom surface of said block having Sone or more than one shallow channel that can receive the ridges on an upper surface of a lower brick when one of said bricks are placed one on top of the other, the channels being flanked by longitudinally extending flat 00 outer foot portions corresponding in width to said outer Ssupport surfaces; and wherein any one or more of the following portions of the block is in the form of bevelled surface: a junction of the top surface of the block and the front panel; a junction of the top surface of the block and the rear panel; an outer right corner of the front panel; an outer right corner of the rear panel; an outer left corner of the front panel; and an outer left corner of the rear panel, and wherein the front and/or rear panels include a vertical groove that can receive a complementary ridge protruding from the end of another block such that said other block can be inter-fitted in a lateral position with the corner block to form a corner structure.

9. The corner block according to claim 8, wherein said other block is the construction block according to any one of claims 1 to 7.

10. The corner block according to claim 8, wherein a right edge surface of said front and rear panels have first and second profiles respectively, and the left end of the block includes an end web interconnecting the front and rear panels, and the first and second profiles are complementary to said first and second profiles of said construction blocks according to any one of claims 1 to 7 to permit the corner block to interfit end-to-end with H:\Pcabral\Keep\speci\p55075.doc 13/12/04 14 Ssaid construction block.

11. The corner block according to claim 8, wherein the Sleft edge surface of the said front and rear panels have first and second profiles respectively and an end web interconnecting the front and rear panels at the right end of the block, and the first and second profiles are 00 complementary to the first and second profiles of said Sconstruction block according to any one of claims 1 to 7 to permit the corner block to interfit end-to-end with Ssaid construction block.

12. The corner block according to claim 9 or wherein the front and rear panels each have one of said vertical grooves so that one of said construction blocks having a complementary ridge can be positioned laterally on opposite sides of the corner block.

13. The corner block according to any one of claims 8 to 12, substantially as hereinbefore described with reference to the accompanying figures.

14. The construction block according to any one of claims 1 to 7, substantially as hereinbefore described with reference to the accompanying figures. H:\Pcabral\Keep\speci\p55075.doc 13/12/04