AU759446B2 - Renda brick - Google Patents

Description

4 1

AUSTRALIA

Patents Act 1990 DANNY W HILLS COMPLETE SPECIFICATION STANDARD PATENT Invention Title: The Renda Brick The following statement is a full description of this invention including the best method of performing it known to us:- 0.

0 The invention relates to improvements in the building walls, posts, piers and the like, including the most common would be the brick veneer residential house. In order to create a brick veneer wall, bricks, a brick layer, sand, cement, limil, wall ties, paper fasteners, a carpenter, timber for frame, nails, a plasterer, plaster board, glue, timber or steel door frames, timber or steel window frames, flashing, steel or timber lintels for openings, insulation for heating and cooling, white ant and vermin proofing are all required.

The Renda Brick has been designed to eliminate most of the above. It is a hollow brick with the sides having a continuation of holes which can be made any size and can be made from many materials, such as: plastic, cardboard, wood, steel, fibre, concrete, clay, fibre glass, glass, polystyrene, aluminium, and many other materials.

The renda brick will not only be a faster stronger method of building but also by using recycled plastic as the primary ingredient it would have a positive environmental impact.

Statement of Invention In a first aspect, the invention provides a form for use in the construction industry as an integral and modular building element comprising a hollow formwork substantially mimicking a house brick or the like, said formwork including one or a 20 plurality of face surfaces characterised by having a plurality of apertures and one or a plurality of abutting surfaces having communication ports wherein said formwork further includes joining means for joining adjacent formworks together for cooperation by aligning said face surfaces and said communication ports such that when said formwork is filled with concrete or the like filler, said filler migrates throughout the plurality of formworks via said communication ports and a portion of said filler exudes from the hollow inside of said formwork face surfaces via said apertures thereby providing an integral rendering medium for said formwork.

The apertures may be provided in the form of an array of holds in the face surface which are dimensioned to allow controlled transfer of the concrete or filler 30 material across the face surface so as to provide a medium suitable for rendering on the face surface.

The face surface may also incorporate a plurality of linear corrugations incorporating said apertures so as to provide a plurality of crests and valleys at said face surface. The corrugations provide additional surface area for purchase of the rendering material with the corrugations presenting a recurring series of crests, valleys and rises z Y in the face surface.

m:\maw\speci\500000\501157cmpmaw.doc The abutting surfaces of the hollow formwork are those surfaces designed to abut consecutive or subsequent forms and these surfaces are provided with communication ports in the form of large apertures or holes in the surface comprising the majority of those particular surfaces.

The hollow forms may also be provided with joining means to assist in the cooperation and interlocking between adjacent forms and the joining means can take the form of protruding lugs or channels and corresponding recesses so as to allow the forms to be engaged in a regular and cooperative manner.

To assist with understanding the invention, reference will now be made to the accompanying drawings, which show one example of the invention.

Fig. 1 is a form configured in the shape of a house brick. The form itself can be made in various ways and therefore can vary. The corrugations can be round, square, it can be just a flat surface with holes. The hole sizes may vary depending on the type and consistency of the mixture flowing through the brick. In this case, the surface is corrugated.

Fig. 2 is a form configured in the shape of a corner half brick.

S• Fig. 3 is a form configured in the shape of a rebated brick.

Fig. 4 is a form configured in the shape of a sill brick.

20 Fig. 5 is a section of a wall showing how the filler mixture extrudes being the external part of the wall through the apertures of the fall surface, allowing it to be screeded off and the form disappears beneath the mixture.

No. 1 Mixture poured into wall.

No. 2 Steel rods can be placed vertical and horizontal for added strength and for shrinkage.

Fig. 6 shows a partly constructed wall with the rebated will shaped form and rebated wall brick shaped form.

:No. 1 Rebated sill brick.

No. 2 Rebated wall brick.

30 Fig. 7 is a half brick shaped form.

Fig. 8 is a full brick shaped form.

Fig. 9 is a rebated full brick shaped form, no top to allow for steel mesh to be placed.

;peci\500000\501.157cmpmaw. doc Detailed Description of the Invention The invention will now be described with reference to the Figures and in particular Figures 1 and 2 which detail the form of the invention which is manufactured in the general shape and configuration of a standard house brick. The hollow formwork 1 comprises the hollow structure of the invention that is adapted to receive a filler in the form of concrete or other workable and settable means. The particular design of the hollow formwork of the invention provides for the receipt of the filler means such that the filler can migrate in a controlled manner from within the interior of the hollow formwork. The formwork 1 has one or more face surfaces 2 which are adapted for presentation in the finished construction. For example, the face surfaces would mimic those surfaces of a house brick which would appear on the exterior of the building once the construction is finished. The face surfaces are provided with a plurality of apertures 3 which are the conduit and means by which the filler material exudes from the inside of the hollow formwork to the face surface thereby presenting a measurable and controlled amount of filler material which can subsequently be rendered so as to form the final finished surface for the face of the form. The hollow form is also provided with a plurality of abutting surfaces 4 being those surfaces which are adapted for contiguous abutment to subsequent or adjacent forms. The abutment surfaces are **.provided with large communication ports 5 so as to provide a ready means of 20 movement and flow of the filler material throughout the mosaic of hollow formworks that are built up during the construction of a wall or other structure.

In order to facilitate the cooperation of the various hollow formworks in the same manner as a plurality of house bricks would be joined together, the hollow formwork of the invention is provided with joining means 6 which can take the form of protruding lugs or protruding channels where corresponding recesses are provided in other parts of the hollow formwork so that a plurality of formworks can be S"interconnected in a manner similar to that of a child's set of building bricks.

.oo .*The apertures provided in the face surface are most preferably provided in a S* multiple array so as to ensure even distribution and transmission of filler material to the 30 face surface. The apertures are dimensioned in accordance with the type of filler used so that the extrusion rate is sufficient to allow rendering in a controlled manner. In order to provide additional purchase for the rendered surface, the face surface may be provided with a plurality of linear corrugations which present a series of consecutive valleys 7, crests 8 and rises 9 all of which are provided with arrays of apertures.

Referring now to Figures 3 and 4, various configurations of the formwork of the S invention is shown mimicking different shaped house bricks and incorporating all the m:\maw\speci\500000\501157cmpmaw.doc features of the invention in a manner that clearly demonstrates the potential of the invention where hollow forms of various configurations can be dry assembled to resemble a construction comprising a plurality of house bricks including corner bricks, chamfered bricks, sill bricks etc, once the face surfaces thereof are rendered.

Referring now to Figure 5, a cross section end view of the formwork of the invention is shown where a first run of hollow formwork 1 has been applied to a solid foundation 12 and fitted thereto by way of reinforcing rods 11. A subsequent run of formwork is seen in partial section applied to the top thereof taking advantage of the fixing means 6. The filler material has partially filled the lower run and can be seen to have exuded through the face surface so as to provide a renderable surface thereon.

Referring now to Figure 6, a partially completed wall incorporating three lower courses and a sill brick have been assembled wherein access to the assembled hollow formwork is achieved by way of the exposed communication ports 5 which allow the filler material to be disposed within the assembled formworks and a partial representation of the resultant render is detailed in three of the corner bricks.

Figures 7, 8 and 9 show various other configurations of the formwork of the invention but are representative only and the hollow formwork of the invention can of course take any shape or configuration required to construct the appropriate type of Swall required.

20 The forms are open each end except when used on the ends and corners of walls, the sides and ends of the form are corrugated and have as many holes as possible. (Figs.

1 to 9. Note holes are continuous) The hole sizes may vary from time to time. The type of mixture being poured would determine the hole sizes.

The forms are locked together to form walls, posts, columns, retaining walls, window sills, rebated door and window jambs.

The forms can be locked together to form the walls for a house, the rebated forms can be used to form the door and window jambs, internal and external, the sill S shaped forms are used for window sills.

30 Depending on soil conditions and an engineer designing the required steel work, the form of the invention can also be used as an above ground foundation, again another improvement on the existing foundation being poured into the ground.

Once the forms are all locked together, a filler mix is poured into the wall forming a solid wall. As the mixture flows through the wall a small percentage extrudes out of each hold on the face surface sides, corners and ends as appropriate of each form, forming a slurry similar to toothpaste coming from a tube. As the walls are m:\maw\speci\500000\501157cmpmaw.doc continuing to be poured the material that has come through the holes is smoothed off or can be left to go off so a further coat can be added later.

Once the process is complete the original form or forms can no longer be seen, it has been totally covered by the mixture that has flowed through the holes or that has been applied at a later date. In either case the thousands of finger like shapes are there to hold the surface finish.

It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

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Claims (7)

1. A form for use in the construction industry as an integral and modular building element comprising a hollow formwork substantially mimicking a house brick or the like, said formwork including one or a plurality of face surfaces characterised by having a plurality of apertures and one or a plurality of abutting surfaces having communication ports wherein said formwork fUrther includes joining means for joining adjacent formworks together for cooperation by aligning said face surfaces and said communication ports such that when said formwork is filled with concrete or the like filler, said filler migrates throughout the plurality of formworks via said communication ports and a portion of said filler exudes from the hollow inside of said formwork face surfaces via said apertures thereby providing an integral rendering medium for said formwork.

2. A form according to claim 1 wherein said apertures form an array of holes in the face surface dimensioned to allow the transfer binding agent and small aggregate of .*said concrete or filler access to the face surface of said form so as to provide a medium suitable for rendering on said face surface.

3. A form according to claim 1 or claim 2 wherein said face surface has a plurality of linear corrugations presenting a plurality of crests and valleys to said face surface.

4. A form according to claim 3 wherein said apertures are formed in said crests, valleys and rises of said face surface.

5. A form according to any one of claims 1 to 4 wherein said abutting surfaces have communication ports which occupy the majority of the surface area of said abutting surface. 30

6. A form according to any one of claims 1 to 5 wherein said joining means include protruding lugs or channels and corresponding recesses for cooperation therewith. m:\maw\speci\500000\501157cmpmaw.doc 8

7. A form according to any one of claims 1 to 6 substantially as hereinbefore described with reference to the figures. Dated this twenty-ninth day of January 2003 DANNY W HILLS Patent Attorneys for the Applicant: F B RICE CO r m:\maw\speci\500000\501157cmpmaw.doc