CA2651640A1 - Improvements relating to a concrete masonry hollow block - Google Patents
Improvements relating to a concrete masonry hollow block Download PDFInfo
- Publication number
- CA2651640A1 CA2651640A1 CA002651640A CA2651640A CA2651640A1 CA 2651640 A1 CA2651640 A1 CA 2651640A1 CA 002651640 A CA002651640 A CA 002651640A CA 2651640 A CA2651640 A CA 2651640A CA 2651640 A1 CA2651640 A1 CA 2651640A1
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- Prior art keywords
- block
- perimeter
- building
- blocks
- extending
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C1/00—Building elements of block or other shape for the construction of parts of buildings
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C1/00—Building elements of block or other shape for the construction of parts of buildings
- E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
- E04B1/04—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2/14—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element
- E04B2/16—Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element using elements having specially-designed means for stabilising the position
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2002/0202—Details of connections
- E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
- E04B2002/0208—Non-undercut connections, e.g. tongue and groove connections of trapezoidal shape
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2002/0202—Details of connections
- E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
- E04B2002/021—Non-undercut connections, e.g. tongue and groove connections of triangular shape
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2002/0202—Details of connections
- E04B2002/0204—Non-undercut connections, e.g. tongue and groove connections
- E04B2002/0213—Non-undercut connections, e.g. tongue and groove connections of round shape
Abstract
A building block having a body with three sets of opposing outer sides defining thereby a generally rectangular outer shape, the body having at least one passageway having an upper open end at a top of the block and an open lower end at a bottom of the block. An inner part of the block is comprised of a first material, and a second different material surrounds the inner part providing thereby an at least substantially continuous outer surface of said second material. A one side of a one of the sets of opposing sides having at least one protrusion extending outwardly from a planar surface of the side, and at least one cavity in the further opposed side of the same set of opposed sides in a position and of a size to receive and effect an alignment of a further block having the same shape and size of this first defined block, by receiving a or the protrusions into the cavity or cavities.
Description
CA 02651640 2008-11-10 PCT/AU2007/00062:
Received 7 March 200 IMRROVEMENTS RELATING TO A CONCRETE MASONRY HOLLOW
BLOCK.
TECHNtCAL FIELD This disclosure relates to a concrete masonry unit such as a building block, a s construction with concrete masonry units, and a method of construction using these ooncrete masonry units.
BACKGROUND ART
In this specification unless the contrary is expressly stated, where a document, act or Item of knowledge is referred to or discussed, this reference or to discussion is not to be construed as an admission that the document, act or item of knowledge or any combination thereof was at the priority date, pubticiy available, known to the public, part of common general knowledge; or known to be relevant to an attempt to solve any problem with which this specification is Concerned 15 It is known to use concrete hollow blocks for building. These are traditionaily made from a very dry no-slump concrete being a cement and aggregate mixture. This mixture is compressed and/or vibrated while in a mould to an extent to be self-supporNng, and then subsequently quickly removed from the mould and handled for curing and other treatment away from the mould.
zo Such traditional blocks also are traditionally used In construction by using a wet mortar bed on which each block is supported. Each block is adjusted in position by a skiil@d trade3m0.n to be appropriatpty aligned, then the rnortar is left to cure_ Such cure can take such time that It may limit the number of blocks that can be focated one above the other in a singie session.
Amended Sheet IPEA/AU
Received 7 March 206 2 Costs associated with the construction then are driven by a need for skilled tradesman to prepare each mortar bed, apply end mortar where the block none the less Is very heavy in most cases, and then adjust a final locatjon for alignment of the block with other of the blocks already positioned.
A further challenge with traditional masonry concrete blocks is their appearance.
An object of this invention is to reduce at least to some extent one or more of the above difficulties.
Other objects and advantages of the present invention will become apparent io from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present Invention is disclosed.
DlSCbOSURE OF THE INVENTION
In one aspect of this disclosure there is proposed a building block having a is body with three sets of opposing outer sides defining thereby a generally rectangular outer shape, the body having at least one passageway having an upper open end at a top.of the block and an open lower end at a bottom of the block, an inner part of the block being of a first material and a second different material from said first material providing a facing on at least selected outer ao surfaces thereof, and a one side of a one of the sets of opposing sides having at least one protrusion extending outwardly from a planar surface of the side, and at least one cavity in the further opposed side of the same set of opposed sides in a position anci of a size to receive and effect an alignment of a further block having the same shape and size of this first defined block, by receiving a 2s or the protrusions into the cavity or cavities.
Preferably, the second material is denser than the first material.
Amended Sbeet IPEA/AU
CA 02651640 2008-11-10 YUDAU20117/tHU62' Received 7 March 2005 Preferably, the second material is a cementitious material.
Preferably, the second material is made from a mix comprising at least in the main, cement, sand and water.
. . -Preferably, the first material is a mixture of expanded plastic particles and a 6 cementitious binder_ Preferably, the first material is a mixture including at least in the main, cement, sand, water and expanded polystyrene beads. Preferably, the first material includes an additive to ensure that the expanded polystyrene particles or beads are compatible with the wet mixture, and be io mixable therewith.
Preferably, the additive is added to the water prior to the dry components being added to the same.
Preferably, the outwardfy extending protrusion extends from an upper face of ~- the block, and the cavity is formed in the bottom or underneath face of the . , 15 block, and wherein in use, the cavity is adapted to accept an outwardly extending protrusion of a further block for the purpose of joining and causing to be aligned the two building blocks_ Preferably, one or more slots divide the outwardly extending protrusion, so that a further block can register and nest therewith in either an overlapping or fulty 2o coincident registering position_ Preferably, the protrusions are substantially rounded.
Preferably, In the alternabve, the protrusions are of a substantially rectilinear shape Amended Sbeet TPEA/AU
CA 02651640 2008-11-10 PCT/AU2007/00062:
Received 7 March 200~
Preferably, the protrusions are orthogonaliy symmetrical with respect to the block, Preferably, there are two passageways extending between the top and bottom of the block, these being divided by a wall extending between side walls of the block so as to be integral therewith.
Preferably, the cavity is defined by a skirt extending around a lower perimeter of the block so as to be Integral therewith.
In a further aspect, the disclosure may include a building block of wet cast cement having, as integral portions, two oppositely positioned side walls and two oppositeiy positioned end walls which together define at least one Inner passageway extending fully through the block from a bottom to a top thereof, an outer, uppermost perimeter of the block being substantlally withln a single plane, and a portion of the respective walls behind the outer uppermost perimeter being higher than the outer uppermost perimeter, an outer, lowermost perimeter of the respective walls together afl being within a single plane, and a portion of the respective walls behind the outer lowermost perimeter being higher than the outer perimeter, and wherein said latter portion is positioned and shaped so that it provides a receiving shape, where an identical block, if resting on the first block so as to have aligned outer most side faces, would have its outer lowermost perimeter substantially coincide with the outer uppermost perimeter of the first block.
In a further aspect, the disclosure may include a building block of wet cast cement having, as integral portions, two oppositely positioned side walls and two oppositeiy positioned end wans which togetiier define at least one inner passageway extending fully through the block from a bottom to a top of the block, an outer uppermost perimeter of the respective walls together all being within a single plane, and a portion of the respective walls behind the upper outer uppermost perimeter being higher than the outer perimeter, an outer Amended Sheet IPEA/AU
CA 02651640 2008-11-10 PCT/AU2007/00062.
Received 7 March 200 {
lowermost perimeter of the respective walls together all being within a single plane, and a portfon of the respective walls behind the outer lowermost perimeter being higher than the outer perimeter, and wherein said latter portion is positioned and shaped so that it provides a receiving shape where an 5 identical block, if resting on the first said block so as to have aligned outermost side faces, would have its outer lowermost perimeter substantial coincide with the outer uppermost perimeter of the first said block.
In a lurther aspect, the disclosure may include a building block which is of substantively rectangular external shape with two oppositely positioned outer lo sldes, two opp4siteiy positioned outer ends and a top and bottom, a hollow passageway extending fully through the block from the top of the block through to the bottom of the block, a plurality of protrusions each extending above a plane defined by a top of the block, each protrusion being located so as to have an inner side adjacent or adjoining to extend along a portion of a perimeter at a is top of the hollow passageway, and one or more receiving cavities extending into the planar surface of the bottom of the block, the or each cavity corresponding in shape and location so as to receive a one or more protrusions extending into the bottom surface, and where the respective protrusions and cavity or cavities are in respectively mutually corresponding positions.
2o In a further aspect, the disclosure may include a construction In which a firs#
building block as described above, is positioned on a second, substantially identical block, the first block having upwardly directed protrusions engaging corresponding cavities within the underneath face of the second block.
Preferably, the respective biocks are held together by a building adhesive.
2s In a further aspect, the disclosure may include an assembly of at least two blocks, each of which is as described above, where the dimensions and shape of a first of the blocks are substantially identical to the dimensions and shape of a second of the blocks, where the first of the blocks is positioned above and Amended Sheet IPEA/AU
CA 02651640 2008-11-10 PCT/AU2007100062:
Received 7 March 2001 6 }
aligned to have a front and rear face of each define a common plane and where the first block with its bottom face is resting on, directty aligned and adhering by a thin adhesive interface extending at least substantialiy between the two mating faces of the respective blocks.
The term "wet cast concreten is used to distinguish this concrete as requiring somewhat longer in a mould before it can be released as compared to blocks using very dry no-slump ooncrete, which is compressed andfor vibrated into a compact mass that can be removed from a mould very promptly after such a process, and can be cured out of the moutd.
In this respect, before explaining at least one embodiment of the invention in detail, it Is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawing. The invention is capable of embodiments in addition to those described and of being practiced 1 5 and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting_ The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate certain embodiments of the invention, and together 2o with the description, serve to explain the principles of the invention.
Those skilled in the art will appreciate that the conception upon whfch this disclosure is based may readily be utilised as a basis for designing other structures, methods, and systems for carrying out the several purposes of the present invention. It ts Important, therefore, to recognize that the claims should 26 be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCBIP~OF THE DRAWINGS
Amended Sheet CA 02651640 2008-11-10 PCT/AU2007/U006Z:
Received 7 March 200 For a better understanding of this invention it will now be described with reference to one or more exemplary embodiments which shall be described with the assistance of drawfngs wherein:
FIG 1 is a perspective view of a first embodiment from above a block;
s FIG 2 is a perspective view of the first embodiment from below the biock;
FIG 3 is a perspective from above the block but viewing the block from an {
opposite side to the first view In FIG 1;
FIG 4 is a plan view of the same first embodiment;
FIG 5 is a side elevation of the first embodiment with a part cut away;
io FIG 6 is an end view with a part cut away of the first embodiment;
FIG 7 is a perspective view of two blocks according to the first embodiment positioned in a supporting registration and including an adhesive therebetween;
FIG 8 is a cross sectional view of the two blocks one upon the other according to a second embodiment;
ys FIG 9 is a cross sectional view in an opposite alignment of the two blocks as in FIG 8 one upon the other according to the second embodiment;
F!G 10 is a perspective view of blocks according to the second embodiment being joined to illustrate a construction assembly;
FIG 11 is a cross sectional view of a set of blocks according to the second 2o embodiment arranged in an interlocking, joined and adhered arrangement;
FIG 12 is a cross sectionai view of a block according to a third embodiment;
Amended Sheet CA 02651640 2008-11-10 PGT/AU7,007/00062 Received 7 March 200 FIG 13 is a perspective view from above of a fourth embodiment;
FIG 14 is a perspective view of the same fourth embodiment when viewed from below;
FIG 15 is a cross sectional view of the blocks of the fourth embodiment in an assembled arrangement;
FIG 16 is a perspective view of a fifth embodiment;
FIG 17 is a perspective view of the same fifth embodiment when viewed from below;
FIG 18 is a cross sectional view of the blocks of the fifth embodiment; and io FIGS 19 and 20 are perspective views of a sixth embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Now referring to the drawings in detail, rigures 1 through 7 refer to a first embodiment where there is an exemplary block 1 formed of a wet cast cement and having as integral portions, two oppositely positioned (i.e. opposing) side is wails 2 and 3, and two oppositely positioned (i.e. opposing) end walls 4 and 5 where each of these walls 2, 3, 4 and 5 are integrally molded.
The alignment of these respective walls 2, 3, 4 and 5 is such that there is defined therebetween, in this particular case a hollow passageway 6 in the one case, and 7 in the other_ 2o An advantage of these passageways 6 and 7 is that they render the block I
lighter than a block of equivalent size and composition would otherwise be.
Moreover, these cavities provide an insulating effect, which can prove to be Amended Sheet IPEA/AU
CA 02651640 2008-11-10 YCT/AU2VV7A=6Z
Received 7 March 20tk useful both from an energy saving perspective, but also in terms of fire resistance.
There is an intermediate joining waU 8 which extends transversely from wall 2 to wall 3 and is integrally molded therewith as wel!_ s There is provided in this blook an upper outermost perimeter 9 and this substantially defines a plan at 10. With reference to this plan 10 there is a portion of the block exemplified by the respective portions such as at 11, 12, and 14 as examples, which provide a higher part (i.e. form a projection) which is positioned so as to leave a surrounding border area 15 which is a part of the 7o defined plan 10 and the higher portions are set back and, in this embodiment_.
The higher portions (projections) 11 through 14 typically are raised but are separated by portions which leave an area consistent with the plan as in 10 and the purpose of these "slots" shown for instance at 17 and 18 is to allow for a similar block to register and nest appropriately whether in an overlapping or 1s fully coincident registering position.
Rounding these higher portions 11 through 14 as shown in Figures 1 through 12 is considered preferable, because these rounded shapes are more robust than higher portions having sharp edges, which have a greater propensity to chip and break with use.
2o An advantage of the raised portions is that they implicitiy provide a shape which is offset from an outer edge, but is raised therefrom and this implicitly acts as "a flashing" to retard access of moisture therepast. -This effect is to some extent prejudiced by the slots 17 and 18, but the area provided by the slots is relatively small as compared to the overall length of the 25 upper portions 11 through 14 so that the prejudice effect is relatively small.
Amended Sheet IPEA/AU
CA 02651640 2008-11-10 Yl:l%AUZUU%/UUUbl.
Received 71Viarch 2001 10 Now tooking at the underneath side as perhaps shown in Figure 2 but it is also shown in other of the Figures, there is a lowermost outermost perimeter 20 which defines a lowermost plan 21.
In this case, this then provides what might be termed a skirt, which fully surrounds the lowermost portion of the block 1 and inset from this plan 1 is a raised portion 22 the location of which and the height of which relative to the plan 21 is chosen so as to be coincident within several mitlimetres of the respective plan 10 and the raised portions typically 11 through 14.
In this particular case, the dimensions have been chosen so that the area provided by the lowermost plan 21, and to some extent the plan 10, are approximately the same as the area provided by the plan 22 and the plan 16.
When a first block is located on a second block, it can therefore be expected that there will be a sharing approximately equally of the load on face to face contacts and, except to the extent that there is an adhesive in the construction is teehnique in this case, the faces will engage closely one with the other and provide this support.
Further however, an advantage of having an approximately simitar width is that the upper portions during handling are relatively sturdy, and the skirt portion depending from a bottom of the block is also relatively sturdy and will be more resistant to being broken during conventional or even rough handling In a construction site.
It is noted that the underneath side of the block 1 does not attempt to provide separate portions which will fit within respeotive slota ouch as 17 or 16.
The construction of this block 1 is a wet cast construction technique which means that it will depend upon curing of the cement at least to some extent before it can be self supporting and therefore able to be extracted from a die for its forming.
Amended Sheet IPEA/AU
CA 02651640 2008-11-10 YC;1'/AUlU07/0IiU62 Received 7 March 200 . ' This is distinguished then from a conventional compressive masonry cast block system, where very dry or in terms of the trade no or negligible slump concrete is used and use of vibration and or pressure enables rapid extraction from a die, so that it is only subsequent to extraction that any substantive curing of the cement would be expected and this can be achieved in appropriate ways for instance by steam curing or by any other conventional technique.
We are using in this particular embodiment and at least in relation to a substantive part of the application and the invention, portions of the block which are of different characteristics_ io An inner characteristic is of a concrete, which is formed with Portland cement, sand and polystyrene beads.
This has been found to be an effective materiai, which can provide adequate structural strength for the inner part of a block of this type, and an outer part of the block is provided by a separate facing material, which is not including ts material such as expanded plastics.
It is known to treat polystyrene beads with an appropriate coating so that they will be mixable with wet cement especiaily Portland cement and it is proposed in this case that such a mixture should be used. The beads may be treated prior to their addition to the mixture, or indeed the protective additive may be mixed 2o in with the dry mix, or indeed with the water before the dry mix is added.
The advantage of using polystyrene beads is that there can be provided a lightweight concrete which can have an adequate compression strength but can aieo provide a blvck size which makas for economic handling and storage and indeed manufacture, and by providing a facing material which can be of a zs conventional cement sand mix applied and integrated with the inner core material of the foam, sand or other aggregate, and cement, means that overall, the extemal face can be chosen to be decorative, or impermeable to moisture, Amended Sheet IPEA/AU
CA 02651640 2008-11-10 pCT/AU2007M062 Received 7 March 200 12 or otherwise appropriate for other applications, while the inner body provides this adequate support strength and at the same dme the bulk for the purpose needed_ A typical mixture for the inner core material can be as follows (per block): s Polystyrene: 6.5L to 7L
Cement: 4kg to 5kg Sand: 5kg to 5.5kg Water: 1.8Lto2.1L
Supa Plastecizer: 14mL to 20mL
lo Calcium chloride: 5OmL to 65mL
Air entraining agent: 14mL to 2OmL Further to this, a typical outer layer mixture is (per block):
Sand 0.55kg to 0.58kg Cement: 0.3kg to 0_4kg is Polystyrene beads that have been appropriately treated can be purchased from conventional suppliers.
There are features with this block 1 that assist in manufacture and use.
A first of these is that the inner passageway is defined by sides which are aligned to be tapering so that the sides for instance 21 and 22 which are 2o oppositely positioned one with respect to the other and the sides 23 and 24 Amended Sheet IPEA/AU
CA 02651640 2008-11-10 Yl;1/AU2UU7/UUU61 Received 7 March 200 which are also oppositely positioned to each other are tapered so that they have a wider and broader upper mouth than the mouth at the lower end 25-This allows for easier core extraction during manufacture namely subsequent to the block having been cast and ready to be extracted from the die.
This has the advantage of also assisting in die extraction but it also assisis when one block is placed upon another in that this tapered shape acts as a lead in when the bottom of the block 1 is being brought over correspondingly shaped upwardly projecting portions of a similar block beneath it.
The degree of taper can lie within a significant range from as little as 1 or 2 up io to 45 or more to the vertical.
The lowermost cavity shape is defined also by side walls such as at 28 and 29 and these are also then chosen to match the rounded shape of the upwardly projecting portions at 26 and 27_.
The block 1 further includes on an outer uppermost edge, an aris 30 and on a lower outermost edge an aris 31.
In Figure 7, there are two blocks which are now referred to as 32 and 33 which replicate the block of the first embodiment and these are now shown one upon the other in a registered alignment where upwardly projecting portions such as 34 nest within correspondingly shaped cavities.
2o The two blocks have both upper and lower ariss at 35 and 36 and 37 which feature provides to some extent decorative as well as functional feature in minimising accidental chipping of the edge which could then be visually less preferred.
Amended Sheet IPEAJAU
Received 7 March 200 The two blocks in this case 32 and 33 are joined together by a building adhesive material; an appropriate material for this purpose is a conventional cementitious adhesive.
In order to join the two bricks or blocks together, a bead of the adhesive s material is fed onto the respective meeting surfaces and the extent of this spread is such that when the two meeting surfaces come together the adhesive will be caused to spread substantially fully through all of the respective surfaces so as to provide not only an adhesion between the respective surfaces and therefore adhering the blocks together, but also providing a sealing but as well io against water ingress_ The amount of adhesive needed can be judged in practice and is chosen generally so that there is approximately a 2 millimetre separation gap between the meeting surfaces which is just enough to allow for an adhesive body of material and at the same time the dimensions of the respective mating surfaoes is are chdsen to allow for this small separation.
The separation is chosen however so that in practice, once the blocks are positioned, they will be generally centrally aligned and will be sufficiently accurately aligned whether one upon the other or whether in overlapping or corner bonded locations to then need either negligible or no further adjustment 2o in position.
Figure 8 is a cross sectional view through the assembled blocks as shown in Figure 7.
Figure 10 ittustrates the same blook ae in the firet embodiment when uaed in an overlapping arrangement to provide for a construction.
25 The blocks in each case in this instance are half overlapping and there is provided a quarter block 41 to fill the gap created by overlapping the blocks in this fashion.
Amended Sheet IPEA/AU
CA 02651640 2008-11-10 PCT/AU2007ro0062 Reeeiived 71Vlarch 200 The blocks shown here as 40 have the same features as the block in the first embodiment and are held together in this case both by building adhesive as previously described.
The quarter block in this case 41 is made from a solid masonry concrete s material including in this case polystyrene beads and having an outer face consistent with the outer faces of the other blocks 40 which is made during a wet cast molding process to not be so embedded with polystyrene beads or the like. A cross section of the construction as shown in Figure 10 is now shown in io Figure 11 an alternative to the cross sectional shape of the upwardly projecting portions in the block as shown in relation to the first embodiment can be altered and alternatives are now shown through the remainder of the embodiments which for instance is shown in Figure 12 where the upwardly projecting portions shown at 45 takes over as a majoriry of the interface support and there is a t5 much narrower edge at 46 providing the defining plan of the upper outermost edge.
Further, the side wal147 is in case somewhat more extensively sloping.
The blocks otherwise include the polystyrene bead embedded masonry material at 48, an outer facing material formed in a wet cast method but in this case without the embedded polystyrene beads as being shown at 49.
The outer facing material 49 is a higher density material that provides a harder and tougher facing than would the inner core materia148, which is of lesser density. This allowe for s Iarger block for given overall sizes where there may be a weight restraint established by occupational lifting restrictions.
zs The blocks may be adhered together by a building adhesive material feaving several millimetres separation gap at 50 but nonetheless such that this separation is ineidental to the general dimensions of any construction.
Amended Sheet II'EA/AU
CA 02651640 2008-11-10 Y(;17Al1ZIIU7t0U11b2 itcceived 7 March 200 Now referring to Figures 13, 14 and 15, these shown a different upward projecting portion where this is shown as a triangular cross sectional shape as typically at 51.
This can then be centrally located along and a corresponding edge cavity 53 is s in the bottom as shown specifically in Figures 14 and 15.
Figures 16, 17 and 18 illustrate an alternative shape where the upwardly projecting porflons as in 55 with reference to an otherwise defining plan 56 is of rectilinear shape in cross section.
This again has a matching cavity shape as shown in Figure 17 in particular at io 57.
Finally there is shown in Figures 19 and 20, a further variant of the upwardly projecting interlocking shape as shown at 60 with reference to a defining plan 61 and a corresponding cavity shape 62 wtthin the bottom of the block.
Although the invention has been herein shown and described in what is 15 conceived to be the most practical and preferred embodiment, It is recognised that departures can be made within the scope of the invention, which is not to be limited to the details described herein but is to be accorded the full scope of the appended claims so as to embrace any and atf equivalent devices and apparatus.
Amended Sheet IPEA/AU
Received 7 March 200 IMRROVEMENTS RELATING TO A CONCRETE MASONRY HOLLOW
BLOCK.
TECHNtCAL FIELD This disclosure relates to a concrete masonry unit such as a building block, a s construction with concrete masonry units, and a method of construction using these ooncrete masonry units.
BACKGROUND ART
In this specification unless the contrary is expressly stated, where a document, act or Item of knowledge is referred to or discussed, this reference or to discussion is not to be construed as an admission that the document, act or item of knowledge or any combination thereof was at the priority date, pubticiy available, known to the public, part of common general knowledge; or known to be relevant to an attempt to solve any problem with which this specification is Concerned 15 It is known to use concrete hollow blocks for building. These are traditionaily made from a very dry no-slump concrete being a cement and aggregate mixture. This mixture is compressed and/or vibrated while in a mould to an extent to be self-supporNng, and then subsequently quickly removed from the mould and handled for curing and other treatment away from the mould.
zo Such traditional blocks also are traditionally used In construction by using a wet mortar bed on which each block is supported. Each block is adjusted in position by a skiil@d trade3m0.n to be appropriatpty aligned, then the rnortar is left to cure_ Such cure can take such time that It may limit the number of blocks that can be focated one above the other in a singie session.
Amended Sheet IPEA/AU
Received 7 March 206 2 Costs associated with the construction then are driven by a need for skilled tradesman to prepare each mortar bed, apply end mortar where the block none the less Is very heavy in most cases, and then adjust a final locatjon for alignment of the block with other of the blocks already positioned.
A further challenge with traditional masonry concrete blocks is their appearance.
An object of this invention is to reduce at least to some extent one or more of the above difficulties.
Other objects and advantages of the present invention will become apparent io from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present Invention is disclosed.
DlSCbOSURE OF THE INVENTION
In one aspect of this disclosure there is proposed a building block having a is body with three sets of opposing outer sides defining thereby a generally rectangular outer shape, the body having at least one passageway having an upper open end at a top.of the block and an open lower end at a bottom of the block, an inner part of the block being of a first material and a second different material from said first material providing a facing on at least selected outer ao surfaces thereof, and a one side of a one of the sets of opposing sides having at least one protrusion extending outwardly from a planar surface of the side, and at least one cavity in the further opposed side of the same set of opposed sides in a position anci of a size to receive and effect an alignment of a further block having the same shape and size of this first defined block, by receiving a 2s or the protrusions into the cavity or cavities.
Preferably, the second material is denser than the first material.
Amended Sbeet IPEA/AU
CA 02651640 2008-11-10 YUDAU20117/tHU62' Received 7 March 2005 Preferably, the second material is a cementitious material.
Preferably, the second material is made from a mix comprising at least in the main, cement, sand and water.
. . -Preferably, the first material is a mixture of expanded plastic particles and a 6 cementitious binder_ Preferably, the first material is a mixture including at least in the main, cement, sand, water and expanded polystyrene beads. Preferably, the first material includes an additive to ensure that the expanded polystyrene particles or beads are compatible with the wet mixture, and be io mixable therewith.
Preferably, the additive is added to the water prior to the dry components being added to the same.
Preferably, the outwardfy extending protrusion extends from an upper face of ~- the block, and the cavity is formed in the bottom or underneath face of the . , 15 block, and wherein in use, the cavity is adapted to accept an outwardly extending protrusion of a further block for the purpose of joining and causing to be aligned the two building blocks_ Preferably, one or more slots divide the outwardly extending protrusion, so that a further block can register and nest therewith in either an overlapping or fulty 2o coincident registering position_ Preferably, the protrusions are substantially rounded.
Preferably, In the alternabve, the protrusions are of a substantially rectilinear shape Amended Sbeet TPEA/AU
CA 02651640 2008-11-10 PCT/AU2007/00062:
Received 7 March 200~
Preferably, the protrusions are orthogonaliy symmetrical with respect to the block, Preferably, there are two passageways extending between the top and bottom of the block, these being divided by a wall extending between side walls of the block so as to be integral therewith.
Preferably, the cavity is defined by a skirt extending around a lower perimeter of the block so as to be Integral therewith.
In a further aspect, the disclosure may include a building block of wet cast cement having, as integral portions, two oppositely positioned side walls and two oppositeiy positioned end walls which together define at least one Inner passageway extending fully through the block from a bottom to a top thereof, an outer, uppermost perimeter of the block being substantlally withln a single plane, and a portion of the respective walls behind the outer uppermost perimeter being higher than the outer uppermost perimeter, an outer, lowermost perimeter of the respective walls together afl being within a single plane, and a portion of the respective walls behind the outer lowermost perimeter being higher than the outer perimeter, and wherein said latter portion is positioned and shaped so that it provides a receiving shape, where an identical block, if resting on the first block so as to have aligned outer most side faces, would have its outer lowermost perimeter substantially coincide with the outer uppermost perimeter of the first block.
In a further aspect, the disclosure may include a building block of wet cast cement having, as integral portions, two oppositely positioned side walls and two oppositeiy positioned end wans which togetiier define at least one inner passageway extending fully through the block from a bottom to a top of the block, an outer uppermost perimeter of the respective walls together all being within a single plane, and a portion of the respective walls behind the upper outer uppermost perimeter being higher than the outer perimeter, an outer Amended Sheet IPEA/AU
CA 02651640 2008-11-10 PCT/AU2007/00062.
Received 7 March 200 {
lowermost perimeter of the respective walls together all being within a single plane, and a portfon of the respective walls behind the outer lowermost perimeter being higher than the outer perimeter, and wherein said latter portion is positioned and shaped so that it provides a receiving shape where an 5 identical block, if resting on the first said block so as to have aligned outermost side faces, would have its outer lowermost perimeter substantial coincide with the outer uppermost perimeter of the first said block.
In a lurther aspect, the disclosure may include a building block which is of substantively rectangular external shape with two oppositely positioned outer lo sldes, two opp4siteiy positioned outer ends and a top and bottom, a hollow passageway extending fully through the block from the top of the block through to the bottom of the block, a plurality of protrusions each extending above a plane defined by a top of the block, each protrusion being located so as to have an inner side adjacent or adjoining to extend along a portion of a perimeter at a is top of the hollow passageway, and one or more receiving cavities extending into the planar surface of the bottom of the block, the or each cavity corresponding in shape and location so as to receive a one or more protrusions extending into the bottom surface, and where the respective protrusions and cavity or cavities are in respectively mutually corresponding positions.
2o In a further aspect, the disclosure may include a construction In which a firs#
building block as described above, is positioned on a second, substantially identical block, the first block having upwardly directed protrusions engaging corresponding cavities within the underneath face of the second block.
Preferably, the respective biocks are held together by a building adhesive.
2s In a further aspect, the disclosure may include an assembly of at least two blocks, each of which is as described above, where the dimensions and shape of a first of the blocks are substantially identical to the dimensions and shape of a second of the blocks, where the first of the blocks is positioned above and Amended Sheet IPEA/AU
CA 02651640 2008-11-10 PCT/AU2007100062:
Received 7 March 2001 6 }
aligned to have a front and rear face of each define a common plane and where the first block with its bottom face is resting on, directty aligned and adhering by a thin adhesive interface extending at least substantialiy between the two mating faces of the respective blocks.
The term "wet cast concreten is used to distinguish this concrete as requiring somewhat longer in a mould before it can be released as compared to blocks using very dry no-slump ooncrete, which is compressed andfor vibrated into a compact mass that can be removed from a mould very promptly after such a process, and can be cured out of the moutd.
In this respect, before explaining at least one embodiment of the invention in detail, it Is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawing. The invention is capable of embodiments in addition to those described and of being practiced 1 5 and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting_ The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate certain embodiments of the invention, and together 2o with the description, serve to explain the principles of the invention.
Those skilled in the art will appreciate that the conception upon whfch this disclosure is based may readily be utilised as a basis for designing other structures, methods, and systems for carrying out the several purposes of the present invention. It ts Important, therefore, to recognize that the claims should 26 be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCBIP~OF THE DRAWINGS
Amended Sheet CA 02651640 2008-11-10 PCT/AU2007/U006Z:
Received 7 March 200 For a better understanding of this invention it will now be described with reference to one or more exemplary embodiments which shall be described with the assistance of drawfngs wherein:
FIG 1 is a perspective view of a first embodiment from above a block;
s FIG 2 is a perspective view of the first embodiment from below the biock;
FIG 3 is a perspective from above the block but viewing the block from an {
opposite side to the first view In FIG 1;
FIG 4 is a plan view of the same first embodiment;
FIG 5 is a side elevation of the first embodiment with a part cut away;
io FIG 6 is an end view with a part cut away of the first embodiment;
FIG 7 is a perspective view of two blocks according to the first embodiment positioned in a supporting registration and including an adhesive therebetween;
FIG 8 is a cross sectional view of the two blocks one upon the other according to a second embodiment;
ys FIG 9 is a cross sectional view in an opposite alignment of the two blocks as in FIG 8 one upon the other according to the second embodiment;
F!G 10 is a perspective view of blocks according to the second embodiment being joined to illustrate a construction assembly;
FIG 11 is a cross sectional view of a set of blocks according to the second 2o embodiment arranged in an interlocking, joined and adhered arrangement;
FIG 12 is a cross sectionai view of a block according to a third embodiment;
Amended Sheet CA 02651640 2008-11-10 PGT/AU7,007/00062 Received 7 March 200 FIG 13 is a perspective view from above of a fourth embodiment;
FIG 14 is a perspective view of the same fourth embodiment when viewed from below;
FIG 15 is a cross sectional view of the blocks of the fourth embodiment in an assembled arrangement;
FIG 16 is a perspective view of a fifth embodiment;
FIG 17 is a perspective view of the same fifth embodiment when viewed from below;
FIG 18 is a cross sectional view of the blocks of the fifth embodiment; and io FIGS 19 and 20 are perspective views of a sixth embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Now referring to the drawings in detail, rigures 1 through 7 refer to a first embodiment where there is an exemplary block 1 formed of a wet cast cement and having as integral portions, two oppositely positioned (i.e. opposing) side is wails 2 and 3, and two oppositely positioned (i.e. opposing) end walls 4 and 5 where each of these walls 2, 3, 4 and 5 are integrally molded.
The alignment of these respective walls 2, 3, 4 and 5 is such that there is defined therebetween, in this particular case a hollow passageway 6 in the one case, and 7 in the other_ 2o An advantage of these passageways 6 and 7 is that they render the block I
lighter than a block of equivalent size and composition would otherwise be.
Moreover, these cavities provide an insulating effect, which can prove to be Amended Sheet IPEA/AU
CA 02651640 2008-11-10 YCT/AU2VV7A=6Z
Received 7 March 20tk useful both from an energy saving perspective, but also in terms of fire resistance.
There is an intermediate joining waU 8 which extends transversely from wall 2 to wall 3 and is integrally molded therewith as wel!_ s There is provided in this blook an upper outermost perimeter 9 and this substantially defines a plan at 10. With reference to this plan 10 there is a portion of the block exemplified by the respective portions such as at 11, 12, and 14 as examples, which provide a higher part (i.e. form a projection) which is positioned so as to leave a surrounding border area 15 which is a part of the 7o defined plan 10 and the higher portions are set back and, in this embodiment_.
The higher portions (projections) 11 through 14 typically are raised but are separated by portions which leave an area consistent with the plan as in 10 and the purpose of these "slots" shown for instance at 17 and 18 is to allow for a similar block to register and nest appropriately whether in an overlapping or 1s fully coincident registering position.
Rounding these higher portions 11 through 14 as shown in Figures 1 through 12 is considered preferable, because these rounded shapes are more robust than higher portions having sharp edges, which have a greater propensity to chip and break with use.
2o An advantage of the raised portions is that they implicitiy provide a shape which is offset from an outer edge, but is raised therefrom and this implicitly acts as "a flashing" to retard access of moisture therepast. -This effect is to some extent prejudiced by the slots 17 and 18, but the area provided by the slots is relatively small as compared to the overall length of the 25 upper portions 11 through 14 so that the prejudice effect is relatively small.
Amended Sheet IPEA/AU
CA 02651640 2008-11-10 Yl:l%AUZUU%/UUUbl.
Received 71Viarch 2001 10 Now tooking at the underneath side as perhaps shown in Figure 2 but it is also shown in other of the Figures, there is a lowermost outermost perimeter 20 which defines a lowermost plan 21.
In this case, this then provides what might be termed a skirt, which fully surrounds the lowermost portion of the block 1 and inset from this plan 1 is a raised portion 22 the location of which and the height of which relative to the plan 21 is chosen so as to be coincident within several mitlimetres of the respective plan 10 and the raised portions typically 11 through 14.
In this particular case, the dimensions have been chosen so that the area provided by the lowermost plan 21, and to some extent the plan 10, are approximately the same as the area provided by the plan 22 and the plan 16.
When a first block is located on a second block, it can therefore be expected that there will be a sharing approximately equally of the load on face to face contacts and, except to the extent that there is an adhesive in the construction is teehnique in this case, the faces will engage closely one with the other and provide this support.
Further however, an advantage of having an approximately simitar width is that the upper portions during handling are relatively sturdy, and the skirt portion depending from a bottom of the block is also relatively sturdy and will be more resistant to being broken during conventional or even rough handling In a construction site.
It is noted that the underneath side of the block 1 does not attempt to provide separate portions which will fit within respeotive slota ouch as 17 or 16.
The construction of this block 1 is a wet cast construction technique which means that it will depend upon curing of the cement at least to some extent before it can be self supporting and therefore able to be extracted from a die for its forming.
Amended Sheet IPEA/AU
CA 02651640 2008-11-10 YC;1'/AUlU07/0IiU62 Received 7 March 200 . ' This is distinguished then from a conventional compressive masonry cast block system, where very dry or in terms of the trade no or negligible slump concrete is used and use of vibration and or pressure enables rapid extraction from a die, so that it is only subsequent to extraction that any substantive curing of the cement would be expected and this can be achieved in appropriate ways for instance by steam curing or by any other conventional technique.
We are using in this particular embodiment and at least in relation to a substantive part of the application and the invention, portions of the block which are of different characteristics_ io An inner characteristic is of a concrete, which is formed with Portland cement, sand and polystyrene beads.
This has been found to be an effective materiai, which can provide adequate structural strength for the inner part of a block of this type, and an outer part of the block is provided by a separate facing material, which is not including ts material such as expanded plastics.
It is known to treat polystyrene beads with an appropriate coating so that they will be mixable with wet cement especiaily Portland cement and it is proposed in this case that such a mixture should be used. The beads may be treated prior to their addition to the mixture, or indeed the protective additive may be mixed 2o in with the dry mix, or indeed with the water before the dry mix is added.
The advantage of using polystyrene beads is that there can be provided a lightweight concrete which can have an adequate compression strength but can aieo provide a blvck size which makas for economic handling and storage and indeed manufacture, and by providing a facing material which can be of a zs conventional cement sand mix applied and integrated with the inner core material of the foam, sand or other aggregate, and cement, means that overall, the extemal face can be chosen to be decorative, or impermeable to moisture, Amended Sheet IPEA/AU
CA 02651640 2008-11-10 pCT/AU2007M062 Received 7 March 200 12 or otherwise appropriate for other applications, while the inner body provides this adequate support strength and at the same dme the bulk for the purpose needed_ A typical mixture for the inner core material can be as follows (per block): s Polystyrene: 6.5L to 7L
Cement: 4kg to 5kg Sand: 5kg to 5.5kg Water: 1.8Lto2.1L
Supa Plastecizer: 14mL to 20mL
lo Calcium chloride: 5OmL to 65mL
Air entraining agent: 14mL to 2OmL Further to this, a typical outer layer mixture is (per block):
Sand 0.55kg to 0.58kg Cement: 0.3kg to 0_4kg is Polystyrene beads that have been appropriately treated can be purchased from conventional suppliers.
There are features with this block 1 that assist in manufacture and use.
A first of these is that the inner passageway is defined by sides which are aligned to be tapering so that the sides for instance 21 and 22 which are 2o oppositely positioned one with respect to the other and the sides 23 and 24 Amended Sheet IPEA/AU
CA 02651640 2008-11-10 Yl;1/AU2UU7/UUU61 Received 7 March 200 which are also oppositely positioned to each other are tapered so that they have a wider and broader upper mouth than the mouth at the lower end 25-This allows for easier core extraction during manufacture namely subsequent to the block having been cast and ready to be extracted from the die.
This has the advantage of also assisting in die extraction but it also assisis when one block is placed upon another in that this tapered shape acts as a lead in when the bottom of the block 1 is being brought over correspondingly shaped upwardly projecting portions of a similar block beneath it.
The degree of taper can lie within a significant range from as little as 1 or 2 up io to 45 or more to the vertical.
The lowermost cavity shape is defined also by side walls such as at 28 and 29 and these are also then chosen to match the rounded shape of the upwardly projecting portions at 26 and 27_.
The block 1 further includes on an outer uppermost edge, an aris 30 and on a lower outermost edge an aris 31.
In Figure 7, there are two blocks which are now referred to as 32 and 33 which replicate the block of the first embodiment and these are now shown one upon the other in a registered alignment where upwardly projecting portions such as 34 nest within correspondingly shaped cavities.
2o The two blocks have both upper and lower ariss at 35 and 36 and 37 which feature provides to some extent decorative as well as functional feature in minimising accidental chipping of the edge which could then be visually less preferred.
Amended Sheet IPEAJAU
Received 7 March 200 The two blocks in this case 32 and 33 are joined together by a building adhesive material; an appropriate material for this purpose is a conventional cementitious adhesive.
In order to join the two bricks or blocks together, a bead of the adhesive s material is fed onto the respective meeting surfaces and the extent of this spread is such that when the two meeting surfaces come together the adhesive will be caused to spread substantially fully through all of the respective surfaces so as to provide not only an adhesion between the respective surfaces and therefore adhering the blocks together, but also providing a sealing but as well io against water ingress_ The amount of adhesive needed can be judged in practice and is chosen generally so that there is approximately a 2 millimetre separation gap between the meeting surfaces which is just enough to allow for an adhesive body of material and at the same time the dimensions of the respective mating surfaoes is are chdsen to allow for this small separation.
The separation is chosen however so that in practice, once the blocks are positioned, they will be generally centrally aligned and will be sufficiently accurately aligned whether one upon the other or whether in overlapping or corner bonded locations to then need either negligible or no further adjustment 2o in position.
Figure 8 is a cross sectional view through the assembled blocks as shown in Figure 7.
Figure 10 ittustrates the same blook ae in the firet embodiment when uaed in an overlapping arrangement to provide for a construction.
25 The blocks in each case in this instance are half overlapping and there is provided a quarter block 41 to fill the gap created by overlapping the blocks in this fashion.
Amended Sheet IPEA/AU
CA 02651640 2008-11-10 PCT/AU2007ro0062 Reeeiived 71Vlarch 200 The blocks shown here as 40 have the same features as the block in the first embodiment and are held together in this case both by building adhesive as previously described.
The quarter block in this case 41 is made from a solid masonry concrete s material including in this case polystyrene beads and having an outer face consistent with the outer faces of the other blocks 40 which is made during a wet cast molding process to not be so embedded with polystyrene beads or the like. A cross section of the construction as shown in Figure 10 is now shown in io Figure 11 an alternative to the cross sectional shape of the upwardly projecting portions in the block as shown in relation to the first embodiment can be altered and alternatives are now shown through the remainder of the embodiments which for instance is shown in Figure 12 where the upwardly projecting portions shown at 45 takes over as a majoriry of the interface support and there is a t5 much narrower edge at 46 providing the defining plan of the upper outermost edge.
Further, the side wal147 is in case somewhat more extensively sloping.
The blocks otherwise include the polystyrene bead embedded masonry material at 48, an outer facing material formed in a wet cast method but in this case without the embedded polystyrene beads as being shown at 49.
The outer facing material 49 is a higher density material that provides a harder and tougher facing than would the inner core materia148, which is of lesser density. This allowe for s Iarger block for given overall sizes where there may be a weight restraint established by occupational lifting restrictions.
zs The blocks may be adhered together by a building adhesive material feaving several millimetres separation gap at 50 but nonetheless such that this separation is ineidental to the general dimensions of any construction.
Amended Sheet II'EA/AU
CA 02651640 2008-11-10 Y(;17Al1ZIIU7t0U11b2 itcceived 7 March 200 Now referring to Figures 13, 14 and 15, these shown a different upward projecting portion where this is shown as a triangular cross sectional shape as typically at 51.
This can then be centrally located along and a corresponding edge cavity 53 is s in the bottom as shown specifically in Figures 14 and 15.
Figures 16, 17 and 18 illustrate an alternative shape where the upwardly projecting porflons as in 55 with reference to an otherwise defining plan 56 is of rectilinear shape in cross section.
This again has a matching cavity shape as shown in Figure 17 in particular at io 57.
Finally there is shown in Figures 19 and 20, a further variant of the upwardly projecting interlocking shape as shown at 60 with reference to a defining plan 61 and a corresponding cavity shape 62 wtthin the bottom of the block.
Although the invention has been herein shown and described in what is 15 conceived to be the most practical and preferred embodiment, It is recognised that departures can be made within the scope of the invention, which is not to be limited to the details described herein but is to be accorded the full scope of the appended claims so as to embrace any and atf equivalent devices and apparatus.
Amended Sheet IPEA/AU
Claims (22)
1. A building block having a body with three sets of opposing outer sides defining thereby a generally rectangular outer shape, the body having at least one passageway having an upper open end at a top of the block and an open lower end at a bottom of the block, an inner part of the block being of a first material and a second different material from said first material providing a facing on at least selected outer surfaces thereof, and a one side of a one of the sets of opposing sides having at least one protrusion extending outwardly from a planar surface of the side, and at least one cavity in the further opposed side of the same set of opposed sides in a position and of a size to receive and effect an alignment of a further block having the same shape and size of this first defined block, by receiving a or the protrusions into the cavity or cavities.
2. The building block as in claim 1, wherein the second material is denser than the first material.
3. The building block as in claim 2, wherein the second material is a cementitious material.
4. The building block as in claim 3, wherein the second material is made from a mix comprising at least in the main, cement, sand and water.
5. The building block as in any one of the preceding claims, wherein the first material is a mixture of expanded plastic particles and a cementitious binder.
6. The building block as in claim 5, wherein the first material is a mixture including at least in the main, cement, sand, water and expanded polystyrene beads.
7. The building block as in claim 6, wherein the first material includes an additive to ensure that the expanded polystyrene particles or beads are compatible with the wet mixture, and be mixable-therewith.
8. The building block as in any one of the preceding claims, wherein the outwardly extending protrusion extends from an upper face of the block, and the cavity is formed in the bottom or underneath face of the block, and wherein in use, the cavity is adapted to accept an outwardly extending protrusion of a further block for the purpose of joining and causing to be aligned the two building blocks.
9. The building block as in any one of the preceding claims, wherein one or more slots divide the outwardly extending protrusion, so that a further block can register and nest therewith in either an overlapping or fully coincident registering position.
10. The building block as in claim 9, wherein the protrusions are substantially rounded.
11. The building block as in claim 10, wherein the protrusions are orthogonally symmetrical with respect to the block.
12. The building block as in any one of the preceding claims, wherein there are two passageways extending between the top and bottom of the block, these being divided by a wall extending between side walls of the block so as to be integral therewith.
13. The building block as in any one of the preceding claims, wherein the cavity is defined by a skirt extending around a lower perimeter of the block so as to be integral therewith.
14. A building block including two oppositely positioned side walls and two oppositely positioned end walls which together define at least one inner passageway extending fully through the block from a bottom to a top thereof, an outer, uppermost perimeter of the block being substantially within a single plane, and a portion of the respective walls behind the outer uppermost perimeter being higher than the outer uppermost perimeter, an outer, lowermost perimeter of the respective walls together all being within a single plane, and a portion of the respective walls behind the outer lowermost perimeter being higher than the outer perimeter, wherein said latter portion is positioned and shaped so that it provides a receiving shape, where an identical block, if resting on the first block so as to have aligned outer most side faces, would have its outer lowermost perimeter substantially coincide with the outer uppermost perimeter of the first block, and where an inner part of the block is of a first material and there is a second different material from said first material providing a facing an at least selected outer surfaces thereof.
15. A building block including two oppositely positioned side walls and two oppositely positioned end walls which together define at least one inner passageway extending fully through the block from a bottom to a top of the block, an outer uppermost perimeter of the respective walls together all being within a single plane, and a portion of the respective walls behind the upper outer uppermost perimeter being higher than the outer perimeter, an outer lowermost perimeter of the respective walls together all being within a single plane, and a portion of the respective walls behind the outer lowermost perimeter being higher than the outer perimeter, wherein said latter portion is positioned and shaped so that it provides a receiving shape where an identical block, if resting on the first said block so as to have aligned outermost side faces, would have its outer lowermost perimeter substantial coincide with the outer uppermost perimeter of the first said block, and where an inner part of the block is of a first material and there is a second different material from said first material providing a facing on at least selected outer surfaces thereof.
16. A building block which is of substantively rectangular external shape with two oppositely positioned outer sides, two oppositely positioned outer ends and a top and bottom, a hollow passageway extending fully through the block from the top of the block through to the bottom of the block, a plurality of protrusions each extending above a plane defined by a top of the block, each protrusion being located so as to have an inner side adjacent or adjoining to extend along a portion of a perimeter at a top of the hollow passageway, and one or more receiving cavities extending into the planar surface of the bottom of the block, the or each cavity corresponding in shape and location so as to receive a one or more protrusions extending into the bottom surface, where the respective protrusions and cavity or cavities are in respectively mutually corresponding positions, and where an inner part of the block is of a first material and there is a second different material from said first material providing a facing on at least selected outer surfaces thereof.
17. A construction in which a first building block as characterised in any one of the preceding claims directed to a block, wherein the first block is positioned on a second, substantially identical block, the first block having upwardly directed protrusions engaging corresponding cavities within the underneath face of the second block.
18. The construction as in claim 17, wherein the respective blocks are held together by a building adhesive.
19. An assembly of at least two blocks, each of which is characterised as in any one of the preceding claims to a block, where the dimensions and shape of a first of the blocks are substantially identical to the dimensions and shape of a second of the blocks, where the first of the blocks is positioned above and aligned to have a front and rear face of each define a common plane and where the first block with its bottom face is resting on, directly aligned and adhering by a thin adhesive interface extending at least substantially between the two mating faces of the respective blocks.
20. A building block as described in the specification, with reference to and as illustrated in the accompanying representations.
21. A construction as described in the specification, with reference to and as illustrated in the accompanying representations.
22. An assembly of building blocks as described in the specification, with reference to and as illustrated in the accompanying representation.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2006902458A AU2006902458A0 (en) | 2006-05-10 | Improvements relating to a concrete masonry hollow block | |
| AU2006902458 | 2006-05-10 | ||
| PCT/AU2007/000622 WO2007128082A1 (en) | 2006-05-10 | 2007-05-10 | Improvements relating to a concrete masonry hollow block |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2651640A1 true CA2651640A1 (en) | 2007-11-15 |
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|---|---|---|---|
| CA002651640A Abandoned CA2651640A1 (en) | 2006-05-10 | 2007-05-10 | Improvements relating to a concrete masonry hollow block |
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| US (2) | US20090173027A1 (en) |
| EP (1) | EP2021551A1 (en) |
| JP (1) | JP2009536276A (en) |
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| WO (1) | WO2007128082A1 (en) |
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| FR2941476B1 (en) * | 2009-01-26 | 2015-08-07 | Tarmac Materiaux De Construction | METHOD FOR MANUFACTURING CONSTRUCTION BLOCK AND CONSTRUCTION BLOCK |
| CN101886445B (en) * | 2010-07-16 | 2012-06-27 | 王洪飞 | Complex self-thermal insulation wall building block |
| CA2810057A1 (en) * | 2010-09-15 | 2012-03-22 | Mcmaster University | Self-reinforced masonry blocks, walls made from self-reinforced masonry blocks, and method for making self-reinforced masonry blocks |
| CA2784844A1 (en) * | 2011-08-08 | 2013-02-08 | Casey Moroschan | Mortarless hollow core block wall construction system |
| CN102581930A (en) * | 2012-03-14 | 2012-07-18 | 哈尔滨海容新型建材有限公司 | Building block and composite heat-insulation wallboard manufacturing machine, manufacturing method and manufactured product |
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-
2007
- 2007-05-10 BR BRPI0711693-4A patent/BRPI0711693A2/en not_active IP Right Cessation
- 2007-05-10 US US12/299,345 patent/US20090173027A1/en not_active Abandoned
- 2007-05-10 RU RU2008148557/03A patent/RU2008148557A/en not_active Application Discontinuation
- 2007-05-10 AU AU2007247786A patent/AU2007247786B2/en not_active Ceased
- 2007-05-10 WO PCT/AU2007/000622 patent/WO2007128082A1/en active Application Filing
- 2007-05-10 KR KR1020087030086A patent/KR20090021347A/en not_active Application Discontinuation
- 2007-05-10 CN CNA2007800168299A patent/CN101443520A/en active Pending
- 2007-05-10 JP JP2009508055A patent/JP2009536276A/en not_active Abandoned
- 2007-05-10 CA CA002651640A patent/CA2651640A1/en not_active Abandoned
- 2007-05-10 EP EP07718869A patent/EP2021551A1/en not_active Withdrawn
-
2008
- 2008-12-09 ZA ZA200810421A patent/ZA200810421B/en unknown
-
2011
- 2011-06-15 US US13/161,227 patent/US20110239570A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| AU2007247786A1 (en) | 2007-11-15 |
| WO2007128082A1 (en) | 2007-11-15 |
| KR20090021347A (en) | 2009-03-03 |
| RU2008148557A (en) | 2010-06-20 |
| US20110239570A1 (en) | 2011-10-06 |
| CN101443520A (en) | 2009-05-27 |
| EP2021551A1 (en) | 2009-02-11 |
| AU2007247786B2 (en) | 2010-05-13 |
| ZA200810421B (en) | 2010-01-27 |
| JP2009536276A (en) | 2009-10-08 |
| BRPI0711693A2 (en) | 2011-12-06 |
| US20090173027A1 (en) | 2009-07-09 |
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| Date | Code | Title | Description |
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| FZDE | Discontinued |
Effective date: 20130510 |