AU2011235975B1

AU2011235975B1 - H Brick Interlock System

Info

Publication number: AU2011235975B1
Application number: AU2011235975A
Authority: AU
Inventors: Ashlee Nicole Harvey; Elise Claire Harvey; Jacinta Louise Harvey
Original assignee: Harvey Elise Claire Ms
Current assignee: Harvey Elise Claire Ms
Priority date: 2011-07-18
Filing date: 2011-10-12
Publication date: 2012-06-07
Anticipated expiration: 2031-10-24

Abstract

Abstract The 'Brick Interlock System' is a fast brick walling and complete cavity brick system, comprising five principal types of brick and several ancillary service bricks. It has the ability to build a bridged interlocking tongue and groove cavity wall system in one go eliminating conventional cavity brick construction, and does not require a bonding agent such as mortar between the brick courses as a function of construction. There is a vertical brick interlock between each course of bricks and a horizontal brick interlock between each second course of bricks. One course of bricks incorporates the 'H' brick, and a comer 'U' brick being of similar length to the 'H' brick and half the external width. The overlay brick course incorporates -the '0' brick, being of similar external length and width of the 'H' brick, and the 'Key' brick which in addition to its vertical interlock provides the horizontal interlock when the brick wall changes direction. Its external dimensions are one and one half the length of the 'H' brick (and '0' brick) and similar width. The depth of the brick is variable. There are vertical and horizontal mortar recesses incorporated within the brick. Mortar is applied after the completion of the brickwork, to replicate conventional residential housing, which is a key to the fast brick walling system. The 'Brick Interlock System' relies on clay and / or clay shale as its raw material, together with additives including, but not restricted to fly ash, sawdust and sugar. There are no cement additives.

Description

Descrption Background With brick veneer construction, a wood or metal frame holds .up the roof, panelling on the inside walls and a skin of bricks on the outside, that is, the house is holding up the brick. With conventional cavity brick construction, two brick walls are laid side by side and tied together with brick ties and cross cavity* embedment. Both brick walls are load bearing, that is, the brick is holding up the house. Conventionally the external layer is done in a face brick (or a utility brick that is rendered). The internal walls are done in a utility brick that is either rendered and plastered or lined using plasterboard. This method of construction is time consuming and expensive. Double brick construction is beneficial as it has high thermal mass which delays the passage of heat through walls, thereby moderating internal temperatures, which reduces energy costs. Brick veneer construction provides the thermal mass materials on the exterior with insulation material on the interior negating the value of the thermal mass. The 'Brick Interlock System' provides a unique fast brick walling system for double brick residential housing construction resolving the time and cost restraints of this type of construction whilst maintaining the traditional appearance of residential 'bricks and mortar'. Summary Double clay / shale brick refers to a type of brick construction, and not to a type of brick. The 'Brick Interlock System' provides a unique solution to the traditional problems associated with building a double brick cavity wall, and replicates double clay / shale brick both as a type of brick construction and brick. It has the ability to build a bridged interlocking tongue and groove cavity wall system in one go eliminating conventional cavity brick construction, and does not require a bonding agent such as mortar between the brick courses as a function of construction. With vertical and horizontal mortar recesses incorporated within the brick, a bonding agent is applied after the completion of the brickwork, to replicate conventional residential housing.

The five principal types of bricks are laid in courses in a staggered relationship in accordance with conventional residential housing. The first course of bricks incorporates the 'H' brick base, and a 'U' brick being of similar length to the 'H' brick base and half the external width. The overlay brick course incorporates the '0' brick, being of similar external length and width of the 'H' brick base, and the 'Key' brick, with its external dimensions being one and one half times the length of the 'H' brick base and of similar width. The next overlay~ brick course repeats the first course with the 'H' brick replacing the 'H' brick base. There are additional advantageous effects of this fast brick walling invention, including but not limited to; the elimination of trash mortar and brick ties; structurally more stable and superior strength to conventional cavity brick wall construction; higher wall heights and greater lateral stability; more productivity on site as it would be faster to lay than conventional cavity brickwork; easier provision for electrical, plumbing and mechanical service trades and flexibility of modular design. Brief description of drawings The objects and features of the invention may be understood with reference to the following detailed description of an illustrative embodiment of the invention, taken together with the accompanying drawing in which; Figure 1. - 'H' brick base Figure 2. - 'H' brick base front view Figure 3. - 'U' brick Figure 4. - 'U' brick front view Figure 5. - 'U' brick left side view Figure 6. - 'U' brick right diagonal view Figure 7. - 'U' brick right side view Figure 8. - 'U' brick top view Figure 9. - '0' brick Figure 10. - '0' brick front view Figure 11. - '0' brick side view Figure 12. - '0' brick top view Figure 13. - 'Key' brick Figure 14. - 'Key' brick front view Figure 15. - 'Key' brick left side view Figure 16. - 'Key' brick right diagonal view' Figure 17. - 'Key' brick- top view Figure 18. - 'H' brick Figure 19. - 'H' brick front view Figure. 20. - 'H' brick side view Figure 21. - 'H' brick top view Figure 22. - 'U brick services Figure 23. - 'H' brick services Figure 24. - Coner wall first course outside Figure 25. - Comer wall second course outside Figure 26. - Comer wall third course outside Figure 27. - Comer wall fourth course outside Figure 28. - Comer wall first course inside Figure 29. - Comer wall second course inside Figure 30. - Comer wall third course inside Figure 31. - Comer wall fourth course inside The first brick course incorporates the 'H' brick base (figure 1.) and the 'U brick (figure 3.). The second course incorporates the '0' brick (figure 9.) and the 'Key' brick (figure 13.) which locks the brick system in place when the wall deviates in direction. The third course incorporates the 'H' brick (figure 18.) and the 'U' brick (figure 3.). The fourth course repeats the second course, the fifth course repeats the third course and so on.

'U' brick services (figure 22.) and 'H' brick services (figure 23.) are provided within the walling as required. The three dimensional perspective provides; comer wall first course outside (figure 24.), comer wall second course outside (figure 25.), comer wall third course outside (figure 26.), comer wall fourth course outside (figure 27.), comer wall first course inside (figure 28.), comer wall second course inside (figure 29.), comer wall third course inside (figure 30.) and comer wall fourth course inside (figure 31.). Description of embodiment The invention suits any type of housing which requires fast brick walling and would include public and affordable housing, and 'do it yourself' farm buildings. It is of benefit to the mining industry in remote locations with thermal mass particularly beneficial where there are large variations between diumal outdoor temperatures. The 'Brick Interlock System' can be dismantled as the bonding agent such as mortar is not applied in a bonding capacity, which facilitates its recycling and re - use.

Claims

1. The 'Brick Interlock System' is a fast brick walling and a complete cavity brick system. It has the ability to build a bridged interlocking tongue and groove cavity wall system in one go eliminating conventional cavity brick construction, and does not require a bonding agent such as mortar between the brick courses as a function of construction. With vertical and horizontal mortar recesses incorporated within the brick, a bonding agent such as mortar is applied after the completion of the brickwork, to replicate conventional residential housing . An interlocking brick system in which a number of bricks are laid in brick courses in a staggered relationship in accordance with conventional residential housing construction, the system comprises five principal types of brick being the 'H' brick base, the 'U' brick, the '0' brick, the 'H' brick and the 'Key' brick, and two associated ancillary bricks, being the 'U' brick services and the 'H' brick services. The first brick course incorporates the 'H' brick base and the 'U' brick being of similar length to the 'H' brick base and 'H' brick and half the external width. The overlay second brick course (fourth, sixth and so on) incorporates the '0' brick, being of similar external length and width of the 'H' brick, and the 'Key' brick, with its external dimensions being one and one half times the length of the 'H' brick and of similar width. The overlay third brick course (fifth, seventh and so on) incorporates the 'H' brick and the 'U' brick. The System, other than the 'Key' brick comprises a pair of upright rectangular side arms of similar dimension with top and bottom flat surfaces connected by one transverse portion of sufficient depth to provide the interlock in the case of the 'H' brick, and two transverse portions in the case of the '0' brick. The transverse portions represents the tongue and groove interlock section. The tongue is marginally smaller than the groove section and slightly tapered to provide the interlock. The 'Key' brick provides a pair of upright rectangular side arms of varying internal dimension with top and bottom flat surfaces connected by two transverse portions.

2. The 'Brick Interlock System' of claim 1. where the 'H' brick base (figure 1.) has the external dimensions of a square and comprises three sections of equal width with a pair of upright rectangular parallel side arms the length of the brick and the transverse portion, being the groove interlock section, comprising half the length of the side arm and at right angles to side arms, and having flat top and bottom surfaces. The transverse portion is in the centre between the side arms, providing in a plan view, a one quarter hollow section, one half transverse portion and one quarter hollow section. The side arm of the 'H' brick base provides the external face of the walling section and is either abutted to the 'U' brick or other 'H' brick base units to form the first brick course.

3. The 'Brick Interlock System' of claim 1. where the 'U' brick (figure 3.) comprises a transverse portion connected to two parallel side arms at right angles, being equal width of a side arm and half the length of a side arm and having flat top and bottom surfaces. The 'U' brick is engaged when the walling deviates in direction such that a corner is formed, and is applied only to the odd numbered brick courses. It can be placed in any corner configuration provided that the hollowed portion between the side arms faces inwards (from a plan view), that is, the hollowed portion cannot be an external brick face. That being said, within brick course three, the 'U' brick overlays the 'Key' brick in the comer position and effectively wraps around one half of the large hollow section of the 'Key' brick, with half of the side arm of the 'U' brick abutting half of the side of the small hollow section of the 'Key' brick. This provides a vertical continuation of hollow sections between the brick courses. The wall can deviate in any direction providing always that a conventional building footprint is formed. Dimensionally, the 'U' brick is exactly one half of the 'H' brick, and can adjust the building footprint by half a brick depending on how it is positioned in the walling section, thereby providing flexibility in design.

4. The 'Brick Interlock System' of claim 1. where the '0' brick (figure 9.) has the external dimensions of a square and comprises three sections of equal width with a pair of upright rectangular side arms the length of the brick and the two transverse portions, being the tongue and groove interlock section, comprising each one quarter the length of the side arm and at right angles to the side arms, and having flat top and bottom surfaces. The hollow section is in the centre between the side arms, providing in a plan view, a one quarter transverse portion, one half hollow section and one quarter transverse portion. The side arm of the '0' brick provides the external face of the walling section and is either abutted to the 'Key' brick or other '0' brick units to form the second brick course. That being said, within brick course two, the '0' brick overlays two identical half sections of the 'H' brick base and 'H' brick, and is applied only to the even numbered brick courses. The tongue of the '0' brick interlocks with the groove of the 'H' brick base and 'H' brick. This provides a vertical continuation of hollow sections between the brick courses.

5. The 'Brick Interlock System' of claim 1. where the 'Key' brick (figure 13.) has the external dimensions of a rectangle being one and one half times the length of the 'H' brick and of similar width, and comprises the consolidation into one brick of three 'U' bricks, being two 'U' bricks abutting each other and providing a large hollow section, with a third 'U' brick abutting directly below to provide the rectangle, thereby creating a small hollow section. The brick has top and bottom flat surfaces which incorporate two transverse portions, being the tongue and groove interlock section, which abut the large hollow section and the small hollow section in line with the course of bricks. The two external faces of the 'Key' brick without the transverse portions provides the comer of the walling section and is either abutted to the 'Key' brick or other '0' brick base units to form the second brick course. That being said, within brick course two, the 'Key' brick overlays the 'U' brick and two identical half sections of the 'H' brick base and 'H' brick, and is applied only to the even numbered brick courses. The tongue of the 'Key' brick interlocks with the groove of the 'H' brick base and 'H' brick. This provides a vertical continuation of hollow sections between the brick courses. The 'Key' brick provides both the vertical brick interlock and horizontal brick interlock between each course of bricks, which negates the need for a bonding agent between each course, both vertically and horizontally.

6. The 'Brick Interlock System' of claim 1. where the 'H' brick (figure 18.) has the external dimensions of a square and comprises three sections of equal width with a pair of upright rectangular parallel side arms the length of the brick and the transverse portion, being the groove interlock section, comprising half the length of the side arm and at right angles to side arms, and having flat top and bottom surfaces. The transverse portion is in the centre between the side arms, providing in a plan view, a one quarter hollow section, one half transverse portion and one quarter hollow section. The side arm of the 'H' brick provides the external face of the walling section and is either abutted to the 'U' brick or other 'H' brick units to form the first brick course.