AU737866B2 - Building component - Google Patents

Description

-1- P/00/0011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT 0.

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0 000.

ORIGINAL

Name of Applicant: Actual Inventor: Address for service ANTONIO MUCCI Antonio MUCCI in Australia: CARTER SMITH BEADLE 2 Railway Parade Camberwell Victoria 3124 Australia Invention Title: BUILDING COMPONENT Details of Associated Provisional Application: P09039 filed 8 September 1997 The following statement is a full description of this invention, including the best method of performing it known to us -2- BUILDING COMPONENT The present invention relates to building components in the form of bricks and more particularly to a brick adapted for interlocking engagement with a further like brick. The invention is suitable for use in the construction of walls in houses and other buildings without the need to use conventional mortar material between the layers of bricks, and it will be convenient to here and after to disclose the invention in relation to that exemplary application. It is to be appreciated, however, that the invention is not limited to that application.

Interlocking bricks of the general kind contemplated here are known in various forms and generally have some form of projection on the top surface, when in use, and a complimentary recess in the bottom surface. When in use the projection of one brick engages the recess of the brick immediately adjacent and oooo, interlocks therewith.

In the construction industry several problems arise with known interlocking bricks. Firstly, since the bricks are moulded from concrete or clay products, they are brittle and therefore susceptible to damage during handling consequently, end projections or protrusions often suffer damage whereby the bricks become unusable or lose some of the strength of the connection due to part of the projection being broken off. Also, because of their proportions, the shape of known interlocking 20 bricks is not uniform and thus the ability to stack some bricks for transportation and :°•ooo storage purposes is considerably reduced compared to conventional rectangular bricks. Furthermore, the shape of the interconnecting parts of conventional bricks in many cases does not provide a firm interconnection enabling the bricks to be used satisfactorily without bonding material.

In situations where high fire rating of a problem is required, it is desirable to use an interlocking type brick because the bonding material between the more conventional bricks provides a weak point in so far as fire rating is concerned. The abutting surfaces of interlocking bricks provide a much higher fire rating. It is however important with the interlocking bricks that a strong interconnection exists between the bricks so as to provide structural strength to a wall or other structure RNM:GM:#26296.CAP 7 September 1998 -3and not all known interlocking bricks satisfy this requirement.

One attempt to address the above-mentioned problems in relation to conventional construction bricks of the interlocking kind is described in International Patent Application No. WO92/04513, by the present applicant. This document describes a construction brick in the form of a rectangular block which has uniformly spaced cylindrical apertures or recesses in the top and bottom surfaces thereof. Solid cylindrical plugs are provided for insertion into the apertures to fit snugly therein and provide projections for accommodation in a similar manner in the apertures of an adjoining brick when two such bricks are laid in closely abutting relationship. The interlocking of the bricks in this manner provides a strong joint without the requirement for conventional mortar joints between the bricks.

However, it has been found that such constructional bricks, whilst representing a marked improvement over known constructional bricks, nevertheless have a number of deficiencies.

Firstly, whilst the strength of a wall made from such constructional bricks is often adequate, it is sometimes necessary to improve the strength of the joints between the joining bricks. To this end, adhesive may be poured onto the ends of a brick and into the brick recesses prior to the plug being placed therein and an adjacent brick being laid on top of the first brick. Such a process however, is very time consuming and consequently increases the manufacturing cost of a wall using .such constructional brick.

Moreover, the overall strength of a wall made using such constructional bricks is largely dependent upon the material from which the bricks are constructed. For walls required to bear substantial loads, the bricks are generally substantially made from concrete and other heavy material. The considerably weight of such bricks reduces the ease with which they may be handled and adds to the time required to construct walls using such bricks.

Accordingly, it is an object of the present invention to provide an improved constructional brick of the interlocking kind which overcomes one or more of the aforementioned disadvantages of known bricks or at least provides the public with RNM:GM:#26296.CAP 7 September 1998 -4a useful choice.

One aspect of the invention provides a constructional brick of the kind which has, in use: an upper surface and an under surface adapted for interlocking engagement respectively with the under surface and the upper surface of a like brick, one or more holes extending between a first opening in the upper surface and a second opening in the under surface, each opening being adapted receive a separate plug inserted to fit snugly therein to provide a projection for accommodation in a similar manner in an opening of the opposite surface of the like brick when the two bricks are superposed in close abutting relationship, the plug having a passage extending therethrough for communicating holes through the superposed bricks to thereby form a continuous channel for receiving strengthening material poured therethrough.

:ih uIn one embodiment, the plug includes a rim projecting radially outward from the outer surface of the plug.

Conveniently, the rim may be located substantially midway along the plug.

"In one embodiment, the hole may comprise a central portion of a first radial dimension and two end portions, at least one of these end portions having a second radial dimension greater than the first radial dimension to thereby form a lip near at least one of the openings for supporting the plug when it is inserted into an opening.

In one embodiment, the radial dimensions of the central portion and at least one of the end portions are chosen so that the lip supports the radially projecting rim !of the plug when the plug is inserted into an opening.

Preferably, the longitudinal dimensions of at least one end portion are chosen so that the rim is entirely contained within the hole when the plug is inserted in the opening.

Another aspect of the invention provides a construction comprising a plurality of constructional bricks according to any one of the preceding claims, the plurality of constructional bricks being stacked in layers so that the plug inserted into an opening of an upper surface of a first of the plurality of bricks engages in an opening in the under surface of a second of the plurality of bricks, the stacked SRNM:DL40271721 RESI II May 2001 constructional bricks thereby forming one or more continuous channels extending from an opening in the upper surface of each top most constructional brick to an opening in the under surface of each bottom most constructional brick for receiving strengthening material poured therein.

A further aspect of the invention provides a method of forming a construction from a plurality of constructional bricks according to any one of claims 1 to 7, the method including the steps of: inserting a plug into an opening of an upper surface of a first constructional brick, stacking a second constructional brick on top of the first constructional brick so that the plug engages in an opening in the under surface of second constructional brick to thereby form a continuous channel extending through the first and second bricks, repeating steps and until a construction is formed having a continuous channel extending from an opening in the upper surface of each top most constructional brick to an opening in the under surface of each bottom most constructional brick, and o0•oo St pouring strengthening material into one or more continuous channels in .the construction.

The following description refers in more detail the various features of the constructional brick of the present invention. To facilitate an understanding of the invention, reference is made in the description to the accompanying drawings where the constructional brick is illustrated in a preferred embodiment. It is to be understood that the constructional brick of the present invention is not limited to the preferred embodiment as illustrated in the drawings.

In the drawings: Figure 1 is a perspective view from above of a constructional brick according to an embodiment of the invention; Figure 2 is a perspective view similar to Figure 1 but from below; Figure 3 is an end view of the brick; I RNM:DL:40271721 RESI1 11 May 2001 -6- Figure 4 is a plan view of the brick; Figure 5 is a from or rear view of the brick; Figure 6 is a perspective view of a plug for use with the brick according to Figures 1 to Figure 7 demonstrates the interconnection of two like bricks using the plug of Figure 6; and Figure 8 shows a number of like bricks according to the embodiment interconnected to form a structure.

The brick 1 is in the form of a rectangular block having four cylindrical channels or holes extending between an opening in an upper surface 3 and an under surface 4. In this embodiment the channels 2 are uniformly spaced along the length of the brick 1.

According to this particular embodiment, the brick 1 has a height of 250mm, a :.:*.length of 400mm and a depth of 100mm. The apertures 2 are spaced at 40cm centres along the length of the brick. Of course other arrangements for the apertures 2 and for the overall size of the brick will be readily apparent to persons skilled in the art.

S"A plug 5 shown in Figure 6, is dimensioned so as to fit snugly into the channels i: i2 and when two bricks are placed in abutting relationship as shown in Figures 7 and 8 a portion of the plug extends into a channel in both of the two bricks so that a closely abutting joint is formed between these two bricks. In other words, the plug 5 is inserted in a first opening in the upper surface of one brick and when a further brick is superposed or placed on top of the first brick, the plug engages in a similar opening in the under surface of the upper brick.

As seen in Figures 6, 7 and 8, the plug 5 has a passage 6 extending therethrough for communicating the holes in superposed bricks. Accordingly, when the bricks are placed on a proper base or foundation and then stacked in various layers to form the desired construction, a continuous channel is formed extending from an opening in the upper surface of the top most brick in the construction to an opening in the under surface of the bottom most brick in the construction.

As can be best appreciated from Figure 8, such continuous channels provide significant advantages during the manufacture of a desired construction. Firstly, RNM:DL:40271721 RESI I I May 2001 -7mortar, concrete or other strengthening material is able to be conveniently poured into the opening in the upper surface of the top most brick and down through the continuous channel formed through each underlying brick, in one or more of the channels running through the structure, in order to enhance the overall strength of the construction. This enables the step of firstly forming an adhesive barrier along all joints of adjoining bricks to be eliminated. The need to fabricate the constructional bricks from heavy materials such as concrete is also eliminated, since the structural strength of the wall thus formed may be improved, if required, by the pouring of mortar or like material through the continuous channels in the structure. The constructional bricks may therefore be manufactured from lightweight materials, including a significant proportion of polystyrene beads or other lightweight and/or recycled material. Such lightweight bricks are far more convenient to transport, stack and handle than are conventional heavy bricks.

:*The continuous channels formed in the desired structure from the top of the upper most brick to the bottom of the lower most brick, as shown in Figure 8, are also extremely desirable in the construction of internal walls within houses or other S"buildings. Such internal walls often require electrical cabling, water and gas piping, etc to be run through the wall. Existing inner walls generally comprise two thin structures separated by an air gap in which electrical cabling and gas or water piping may be run. These inner walls are generally constructed on a wooden frame to which plaster board is affixed and provide little structural strength. Moreover, such internal Si'" walls are time consuming to construct.

many applications, it may be that mortar or other strengthening material is poured along the entire length of every second, third or fourth channel, in order to strengthen the desired structure, whilst electrical cabling and water or gas piping may be run along one or more of those channels into which the strengthening material is not poured. It will be appreciated that the present invention provides significant advantages in terms of the time taken to construct walls or other structures and then to provide the required cabling or piping within the wall.

Preferably, the plug 5 includes a rim 7 projecting radially outward from the outer surface of the plug. The rim 7 provides a convenient means by which the plug is RNM:DL:40271721 RESI 11 May 2001 -8able to engage with the inner wall of the channel extending through the constructional brick and to fit snugly therein. Conveniently, the rim may be located substantially midway along the plug, so that substantially equal portions of the plug extends into the channels of superposed bricks in the desired structure.

One or more of the holes 2 preferably comprise a central portion 8 having a first radial dimension and two end portions 9 and 10. In this example, the end portion 9 has a second radial dimension greater than the first radial dimension of the central portion 8 together form a lip 11 near an opening in the upper surface 3 of the constructional brick 1. This lip 11 conveniently supports the plug 6 when the plug is inserted into the channel 2.

Preferably, the radial dimensions of the central portion 8 and the end portion 9 are chosen so that the lip 11 supports the radially projecting rim of the plug 5. In the particular embodiment illustrated in the drawings, the first radial dimension (the diameter in the case of a circular cylindrical hole) of the central portion 8 of the hole 2 is 57mm and the second radial dimension of the end portion 11 is 63mm.

The longitudinal dimensions of the end portion 11 may be chosen to that the S.o rim 7 of the plug 5 is entirely contained within the hole 2 when the plug 5 is inserted into the opening on the upper surface 2 of the constructional brick 1. In the illustrated example, this longitudinal dimension is 8mm.

Whilst the constructional brick 1 is shown in the drawings as having holes 2 which include a lip 11 near the openings in the upper surface only of the constructional brick 1, it will be appreciated that in other embodiments of the invention a corresponding lip or lips may be formed near the openings in the under surface 4 of the constructional brick.

The dimensions of the holes 2 and the plugs 5 is such that adjoining layers of bricks have abutting joints whereby no space is lost in the joint. This means that bricks according to the invention may be used to construct a wall which is effectively a smooth wall with no gaps or grooves. Therefore, any rendering supplied over a finished wall may be relatively syncoting as it is not necessary to cover up large gaps or grooves in the wall surface. Accordingly, the base coat of any textured surface F1721 RESI 11 May 2001 e 8afinish may be eliminated. The closely abutting joint and the strength and number of the plugs also contributes to the strength of the joint formed.

Because the brick is formed as a rectangular block with no projections, it may be easily stacked for storage and transportation purposes. The plugs 5 are provided separately and are only inserted into the brick when a desired structure is formed.

Since modifications within the spirit and scope of the invention may be readily effected by persons skilled in the art, it is to be understood that the invention is not limited to the particular embodiment described, by way of example, hereinabove.

*f 71721 RES1 11 May 2001

Claims (11)

1. A constructional brick of the kind which has, in use: an upper surface and an under surface adapted for interlocking engagement respectively with the under surface and the upper surface of a like brick, one or more holes extending between a first opening in the upper surface and a second opening in the under surface, each opening being adapted receive a separate plug inserted to fit snugly therein to provide a projection for accommodation in a similar manner in an opening of the opposite surface of the like brick when the two bricks are superposed in close abutting relationship, the plug having a passage extending therethrough for communicating holes through the superposed bricks to thereby form a continuous channel for receiving strengthening material poured therethrough. iil

2. A constructional brick according to claim 1, wherein the plug includes a rim projecting radially outward from the outer surface of the plug.

3. A constructional brick according to claim 2, wherein the rim may be located substantially midway along the plug. 0 0.

4. A constructional brick according to any one of the preceding claims, wherein the hole may comprise a central portion of a first radial dimension and two end portions, at least one of these end portions having a second radial dimension greater 25 than the first radial dimension to thereby form a lip near at least one of the openings for supporting the plug when it is inserted into an opening. A constructional brick according to claim 4, wherein the radial dimensions of the central portion and at least one of the end portions are chosen so that the lip supports the radially projecting rim of the plug when the plug is inserted into an opening.

RES I S11 May 2001

6. A constructional brick according to either of claims 4 or 5, wherein the longitudinal dimensions of the at least one end portion are chosen so that the rim is entirely contained within the hole when the plug is inserted in the opening.

7. A constructional brick substantially as hereinbefore described with reference to the accompanying drawings.

8. A construction comprising a plurality of constructional bricks according to any one of the preceding claims, the plurality of constructional bricks being stacked in layers so that the plug inserted into an opening of an upper surface of a first of the plurality of bricks engages in an opening in the under surface of a second of the plurality of bricks, the stacked constructional bricks thereby forming one or more continuous channels extending from an opening in the upper surface of each top o 15 most constructional brick to an opening in the under surface of each bottom most S: constructional brick for receiving strengthening material poured therein. o:o oI

9. A construction substantially as hereinbefore described with reference to the o o accompanying drawings.

A method of forming a construction from a plurality of constructional bricks according to any one of claims 1 to 7, the method including the steps of: inserting a plug into an opening of an upper surface of a first constructional brick, 25 stacking a second constructional brick on top of the first constructional brick so that the plug engages in an opening in the under surface of second constructional brick to thereby form a continuous channel extending through the first and second bricks, repeating steps and until a construction is formed having a continuous channel extending from an opening in the upper surface of each top most constructional brick to an opening in the under surface of each bottom most \RNM:DL:40271721 RESI 11 May 2001 11 constructional brick, and pouring strengthening material into one or more continuous channels in the construction.

11. A method according to claim 10, and further including the step of: running electrical or fluid conveying means along one or more continuous channels in the construction into which strengthening material has not been poured. Dated: 21 June, 2001 FREEHILLS CARTER SMITH BEADLE Patent Attorneys for the Applicant ANTONIO MUCCI 21 June 2001