AU2014202310A1 - High Insulation Building System - Google Patents

Abstract

JU4OE-AU-1I A wall block (10) comprises a substantially rectangular core (11) of substantially rigid insulating material which forms structural load bearing elements in a constructed wall. The block (10) has cladding (12) bonded to its lateral surfaces. The cladding (12) is offset from the lateral surfaces with the cladding (12) overhanging from the lower lateral edges, the overhanging portion being adjacent the core (11) of the blocks (10) on the adjacent lower course. The core (11) has a longitudinal void (14) provided in the lower surface along its whole length and at least one vertically extending void (15), extending from the longitudinal void (14) to the upper surface of the core. Furthermore, recesses (21) are formed in the vertical edges of the core (11) and being adapted to receive elongated joint seals (22) to affect sealing of the joints between adjacent blocks (10).

Description

5026E-AU-D1 AUSTRALIA Patents Act 1990 5 COMPLETE SPECIFICATION FOR A STANDARD PATENT 10 ORIGINAL Name of Applicant: T3 ENERGY PTY LTD 15 Actual Inventor: Paul Frederick CURTIS Address for Service: FRASER OLD & SOHN Patent Attorneys PO Box 560 20 MILSONS POINT NSW 1565 Invention Title: HIGH INSULATION BUILDING SYSTEM 25 Details of Parent Application: 2007 207 328 Dated 18 January 2007 The following statement is a full description of this invention, including the best method of performing it known to us: 30 - 1- 5026E-AU-D1 HIGH INSULATION BUILDING SYSTEM Field of the Invention The present invention relates to building systems and, in particular, to a building system which uses prefabricated building components with thermal 5 insulation properties which minimises onsite construction time. Background Art Typical building techniques for domestic dwellings and the like usually start from the floor up with the erection of a structural frame, typically timber or steel. Roof cladding and roof insulation are then added to the frame with wall cladding 10 being similarly applied to the frame with insulation also installed. An internal skin is provided to the walls and ceiling cladding is also usually provided. The process of assembling the frame, insulating and applying cladding inside and outside is highly labour intensive involving a number of skilled trades specialist. Object of the Invention 15 The genesis of the present invention is to provide a building system which is highly insulating and requires minimal labour for its installation onsite. At the very least the object is to provide an alternative to existing building components. Summary of the Invention In accordance with a first aspect of the present invention there is disclosed a 20 wall block comprising a substantially rectangular core comprising a substantially rigid [foamed] insulating material which forms the predominant structural load bearing element in a constructed wall, and the wall block having cladding made of a cementitious material bonded to lateral surfaces of the wall block, wherein the cladding is offset from the lateral surfaces with the cladding overhanging from lower 25 lateral edges, an overhang portion of the cladding overhanging the substantially rectangular core of the wall block on a lower course. -2- 5026E-AU-D1 Preferably, a longitudinal void is provided in the lower surface of the core along its length. Preferably the void takes the form of a centrally located slotted groove. The preferred form also has at least one vertically extending void, the void 5 extending from the longitudinal void to the upper surface of the core. Preferably, the vertically extending void has a frusto-conical shape. In other preferred forms, the frusto-conical shaped void in a wall when formed from the blocks is formed by a pair of semi frusto-conical grooves formed in the end surfaces of adjacent blocks. Preferably, recesses are formed in the vertical edges of the core, the recesses 10 being formed behind the cladding and being adapted to receive elongated joint seals to affect sealing of joint between adjacent blocks. Preferably, the block has mating location devices on the upper and lower surfaces of the core. Preferably these mating location devices take the form of a plurality of mating lugs and recesses. Preferably the lugs and recesses are frusto 15 conical in shape. Preferably the mating location devices are configured in a pattern that enables stacking and alignment of the blocks in a number of ways. For example, the blocks can be stacked directly on top of another, stacked offset by half a block, )usually referred to as stretcher bond), and stacked block upon block with the blocks being offset by 90 degrees, thus forming a corner. 20 In a preferred form, the core has a protective strip bonded to the exposed surface not covered by the cladding. Preferably, the outer lateral surface has a drainage channel provided adjacent the top surface of the core. Preferably, the rigid insulating material is a polyurethane foam material, the 25 cladding is a sheet of cement material, and the protective strip is formed from galvanized steel sheet material. -3- 5026E-AU-D1 In accordance with a second aspect of the present invention there is disclosed method of forming a wall, the method comprising: laying courses of wall blocks on a floor structure, the wall blocks comprising a rectangular core comprising a substantially rigid, foamed insulating material that 5 forms the predominant structural load bearing elements in the constructed wall, with the wall blocks having cladding made of cementitious material and bonded to lateral surfaces of the blocks, wherein the cladding is offset from the lateral surfaces with the cladding overhanging from lower lateral edges, an overhang portion of the cladding overhanging the substantially rectangular core of the wall blocks om on a lower 10 course, and locating the overhanging cladding on the lowest course of the wall blacks blocks against or inadjacent the floor structure. Preferably, a longitudinal void is provided in the lower surface of the core along its length. Preferably the void takes the form of a centrally located slotted 15 groove. The preferred form also has at least one vertically extending void, the void extending from the longitudinal void to the upper surface of the core. Preferably, the vertically extending void has a frusto-conical shape. In other preferred forms, the frusto-conical shaped void in a wall when formed from the blocks is formed by a pair of semi frusto-conical grooves formed in the end surfaces of adjacent blocks. The 20 frusto-conical voids are adapted to align in vertical voids for the height of the wall, whereby the vertical voids are adapted to receive elongated compression means used to compress the course of blocks together. Preferably, the elongated compression means is formed by elongate threaded rods and corresponding nuts and plate devices located at the top and lowest courses of 25 blocks. Preferably, the blocks have recesses which are formed in the vertical edges of the core, the method including the steps of providing elongated joint seals to affect sealing of joint between adjacent blocks, the seals being inserted behind the cladding and in the recesses. -4- 5026E-AU-D1 Preferably, the block has mating location devices on the upper and lower surfaces of the core. Preferably these mating location devices take the form of a plurality of mating lugs and recesses. Preferably the lugs and recesses are frusto conical in shape. 5 In a preferred form, the core has a protective strip bonded to the exposed surface not covered by the cladding. Preferably, the outer lateral surface has a drainage channel provided adjacent top surface of the core. In accordance with a third aspect of the present invention there is disclosed a 10 wall formed by a plurality of blocks as described above. Brief Description of the Drawings An embodiment of the present invention will now be described with reference to the drawings in which: Fig. 1 is a perspective view of a wall block of a preferred embodiment, 15 Fig. 2 is a side elevation view of the wall block of Fig. 1, Fig. 3 is a plan view of the wall block of Fig. 1, Fig. 4 is an end elevation view of the block of Fig. 1, Fig. 5 is a cross sectional view of a sealing strip used in the vertical joints of two adjacent blocks, 20 Fig. 6 is an exploded cross sectional view of a wall being constructed of the blocks of Fig. 1, Fig. 7 is a partial plan view of a wall constructed of blocks of Fig. 1. Detailed Description 25 As illustrated in the drawings, a high insulation block 10 for building walls and the like includes a substantially rectangular, substantially rigid core 11 made from polyurethane foam with cement cladding 12 bonded to the core 11 on the lateral surfaces. The cladding 12 is offset and extends below the lower lateral surfaces and is able to mate with the cladding 12 on the lower course of blocks 10 as the upper -5- 5026E-AU-D1 portion of the lateral surfaces of the core 11 are not covered by the cladding 12. This portion has a protective strip 13 bonded thereto, the strip preferably being made from galvanized steel. This strip is there to provide protection to the joints from fire and other problems. 5 The core 11 has a centrally located slotted groove or void 14 in the lower surface of the core 11. The slotted groove 14 extends along the length of the core 11. Furthermore, the core 11 has a frusto-conical vertically extending void 15 through the core 11. This void 15 is centrally located within the core 11 whilst two semi frusto conical voids or grooves 16 are located at the end surfaces of the core 11. These 10 grooves 16 form a frusto-conical void when two blocks 10 are placed adjacent each other. It is noted that due to the alignment of the blocks when building a wall, the vertically aligned voids extend from the top to the bottom of the wall. The blocks 10 also have mating location lugs and recesses 17 and 18 located on the top and bottom surfaces of the core 11, respectively. These lugs are preferably 15 frusto-conical in shape and are used to have the correct alignment of the courses of the blocks 10 to ensure the vertically aligned voids as described above are correctly formed. The blocks 10 also have a drainage channel 19 formed at the upper portion left exposed from the cladding 12. This drainage channel 19 is preferably located on the 20 external surface of the block 10. The blocks 10 also have recesses 21 formed in the vertical edges of the core 11. The recesses 21 are formed behind the cladding 12 and when adjacent blocks 10 are abutting, the recesses 21 are adapted to receive elongated vertical joint seals 22 which are spring fitted into the recesses 21. These seals 22 are preferably pressed and 25 folded from steel sheet material with drainage channels 23 formed therein. The blocks 10 as described above are used to construct a wall 30 as seen in Fig. 5. The blocks 10 are formed into course on a floor structure 31. The lowest course is formed onto a course of starter blocks 32 whereby the cladding 12 overhangs the starter blocks 32. As seen in Fig. 6, the lower edges of the cladding 12 -6- 5026E-AU-D1 of the lowermost course of blocks do not bear against the foundation. Thus the cladding 12 is not load bearing. Naturally this a a preferred arrangement and other alternatives are used whereby the cladding may be removed from lowest course, the cladding can overhang 5 or fit into slots in floor structure 31, the floor structure 31 can have a elongated ridge formed therein to replace the starter blocks 32 and the like. Irrespective of the above, courses of blocks 10 are formed with the location lugs 17 and recesses 18 mating to align the blocks 10 correctly. Threaded rods 33 are positioned in the vertically aligned voids and are used with a nut 34 to compress the 10 blocks as well as tying the blocks 10 to the floor structure. The horizontal and vertical voids are used as passageways for services such as electrical and plumbing services. The horizontal voids formed along the length of the blocks 10 provide for lintels over doors and windows as well as for services as described above. The seals 22 inserted into the recesses 21 provide effective water sealing to the 15 vertical joints with the drainage channels 23 located in the seals 22 allowing water to drain away, whilst the overhanging cladding 12 and its compression applied by the threaded rod provides the water sealing to the horizontal joints. If there is any penetration of water the drainage channel 19 allows it to drain away and out from the lower horizontal joint. 20 It is seen that a wall 30 erected from the blocks 11 as described above with internal and external cladding is a load bearing structure, has efficient insulation properties and maintains water and wind exclusion. A bead of non setting mastic is applied between the horizontal and vertical faces as they contact adjacent blocks to act as a draft seal. The wall 30 does not require adhesive between the wall blocks due to 25 the compression applied to the blocks by the threaded rods, accordingly the onsite construction time is minimized and construction costs are reduced. As seen in fig. 7, blocks 10 of the course above are shown in dashes and are offset by the length of half a block 10. The corner block 10 has only half cladding 12 on one of its sides with additional cladding 12 added to one or both ends. The blocks 30 10 are shown in a wall 30 and an opening 31 for a door is shown. -7- 5026E-AU-D1 The foregoing describes only one embodiment of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the present invention The term "comprising" as used herein is used in the inclusive sense of 5 "including" or "having" and not in the exclusive sense of "consisting only of'. -8 -

Claims (29)

1. A wall block comprising a substantially rectangular core comprising a substantially rigid [foamed] insulating material which forms the predominant structural load bearing element in a constructed wall, and the wall block having cladding made of a cementitious material bonded to lateral surfaces of the wall block, wherein the cladding is offset from the lateral surfaces with the cladding overhanging from lower lateral edges, an overhang portion of the cladding overhanging the substantially rectangular core of the wall block on a lower course.

2. The block as claimed in claim 1 wherein said insulation material is foamed.

3. The block as claimed in claim 1 or 2 comprising a longitudinal void in the lower surface of the substantially rectangular core along its length.

4. The block as claimed in claim 3 wherein the void comprises a centrally located slotted groove.

5. The block as claimed in claim 4 comprising at least one vertically extending void, the void extending from the longitudinal void to an upper surface of the core.

6. The block as claimed in claim 5 wherein the vertically extending void has a frusto-conical shape.

7. The block as claimed in claim 6 wherein the vertically extending void having a frusto-conical shape is formed by a pair of semi frusto-conical grooves formed in the end surfaces of adjacent blocks.

8. The block as claimed in any one of claims 1-7 comprising recesses in vertical edges of the core, the recesses being formed behind the cladding and being adapted to receive elongated joint seals for sealing of joint between adjacent blocks.

9. The block as claimed in any one of claims 1-8 comprising mating location devices on an upper and a lower surface of the substantially rectangular core. 9 JU4OE-AU-1I

10. The block as claimed in claim 9 wherein the mating location devices comprise a plurality of mating lugs and recesses.

11. The block as claimed in claim 10 wherein the lugs and recesses have a frusto conical shape.

12. The block as claimed in any one of claims 1-11 wherein the substantially rectangular core has a protective strip bonded to an exposed surface not covered by the cladding.

13. The block as claimed in any one of claims 1-12 wherein an outer lateral surface comprises a drainage channel provided adjacent a top surface of the substantially rectangular core.

14. The block as claimed in any one of claims 1-13 wherein the rigid insulating material is a polyurethane foam material, and the protective strip is formed from galvanized steel sheet material.

15. The block as claimed in any one of claims 1-14 wherein the block has part of the cladding removed from the substantially rectangular core and applied offset at an end of the core enabling the block to form a comer in a wall.

16. A method of forming a wall, the method comprising: laying courses of wall blocks on a floor structure, the wall blocks comprising a rectangular core comprising a substantially rigid, insulating material that forms the predominant structural load bearing element in the constructed wall, with the wall blocks having cladding made of cementitious material and bonded to lateral surfaces of the blocks, wherein the cladding is offset from the lateral surfaces with the cladding overhanging from lower lateral edges, an overhang portion of the cladding overhanging the substantially rectangular core of the wall blocks on a lower course, and locating the overhanging cladding on the lowest course of the wall blocks adjacent the floor structure. 10 JU4OE-AU-1I

17. The method as claimed in claim 16 wherein a longitudinal void is provided in the lower surface of the core along its length.

18. The method as claimed in claim 18 wherein the void comprises a centrally located slotted groove.

19. The method as claimed in claim 17 or 18 wherein the block comprises at least one vertically extending void, the void extending from the longitudinal void to an upper surface of the core.

20. The method as claimed in claim 19 wherein the vertically extending void has a frusto-conical shape.

21. The method as claimed in claim 20 wherein the vertically extending void having a frusto-conical shape is formed by a pair of semi frusto-conical grooves formed in end surfaces of adjacent blocks, the frusto-conical voids being adapted to be aligned in vertical voids for a height of the wall, and the vertical voids being adapted to receive elongated compression means used to compress the course of blocks together.

22. The method as claimed in claim 21 wherein the elongated compression means comprises elongate threaded rods and corresponding nuts and plate devices located at a top and lowest courses of the blocks.

23. The method as claimed in any one of claims 16-22 wherein the blocks comprise recesses which are formed in vertical edges of the substantially rectangular core, the method further comprising the steps of providing elongated joint seals to affect sealing of joint between adjacent blocks, the seals being inserted behind the cladding and in the recesses.

24. The method as claimed in any one of claims 16-22 wherein the block has mating location devices on upper and lower surfaces of the substantially rectangular core. 11 JU4OE-AU-1I

25. The method as claimed in claim 24 wherein the mating location devices comprise a plurality of mating lugs and recesses.

26. The method as claimed in claim 25 wherein the lugs and recesses have a frusto-conical shape.

27. The method as claimed in any one of claims 16-26 wherein the substantially rectangular core has a protective strip bonded to an exposed surface not covered by the cladding.

28. The method as claimed in any one of claims 16-27 wherein the outer lateral surface has a drainage channel provided adjacent a top surface of the substantially rectangular core.

29. A wall formed by a plurality of blocks, the blocks each being as claimed in any one of claims 1-15. Dated this 2 9 th day of April 2014 T3 ENERGY PTY LTD BY FRASER OLD & SOHN Patent Attorneys for the Applicant 12