Classifications

• • 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
  • E04B2/22—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 a general shape differing from that of a parallelepiped
• • 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
  • E04B2002/0243—Separate connectors or inserts, e.g. pegs, pins or keys
  • E04B2002/0247—Strips or bars
• • 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
  • E04B2002/0256—Special features of building elements
  • E04B2002/026—Splittable building elements

Definitions

• the present invention relates to a stackable construction block, to a construction block assembly incorporating at least one such stackable construction block and to a building comprising at least one such construction block assembly.
• SIP structural insulated panel
• EPS expanded polystyrene foam
• XPS extruded polystyrene foam
• OSB oriented strand board
• a further such alternative material is insulating concrete form ("ICF”), which is a system of formwork for concrete that remains as a permanent fixture in a building.
• ICF insulating concrete form
• the forms are interlocking modular units, having an internal cavity, that are dry-stacked in columnar form (without mortar) in situ and subsequently filled with concrete. After the concrete has cured, the units remain in place permanently.
• a reinforcing element e.g. steel rebar
• ICFs are currently manufactured from EPS, XPS, cement-bonded wood fibre and cement-bonded polystyrene beads.
• a stackable construction block comprising at least one open-ended channel extending across a surface thereof adapted to receive a block-joining element.
• the surface over which the open-ended channel extends typically may be an exterior surface of the block.
• a plurality of open-ended channels may be provided in the same or different surfaces, preferably exterior surfaces, of the block.
• the channels in the plurality of open-ended channels may be non-identical so as to accommodate different block-joining elements.
• a stackable construction block according to the invention may be formed from a polymeric material.
• Suitable polymeric materials include expanded polystyrene and expanded polypropylene, as such materials have desirable thermal and acoustic insulative properties.
• such polymeric material may be lightweight, for example having a density of no more than 45 kg/m 3 , and preferably no more than 20 kg/m 3 which may be useful when transporting one or multiples of such blocks, particularly by a person, is considered.
• a stackable construction block according to the invention may be substantially L-shaped when viewed in plan from above or below. Such a shape is immediately useful for the formation of corner pillars of buildings. With such L-shaped blocks, the two limbs of the "L" may be of substantially identical dimensions. At least one of the dimensions of the block is preferably at least 300 mm, and possibly at least 450mm or at least 600 mm.
• a cut-out may be provided at the elbow portion of the L-shaped block.
• Such a cut-out may be provided to aid with accurate location of the block in situ during construction; the cut-out may be sized so as to provide suitable abutment to a corner post.
• the corner post may be square or rectangular in cross-section, and the cut-out may be suitably, correspondingly shaped and sized.
• the cut-out may be provided to accommodate a downpipe extending from guttering, and thus may be appropriately sized and shaped.
• a stackable construction block according to the invention especially when in the form of an L-shaped block as hereinbefore described, may be adapted to be separable into two, non-identical, substantially rectangular blocks.
• a rectangular block may be useful for the formation of a non- corner pillar of a building, e.g. a pillar between two window openings, or between a window opening and a door opening.
• at least one separation line may be provided to indicate the location for separation of the L-shaped block into the two rectangular blocks.
• the separation line may be in the form of a surface indication or a surface indentation.
• a stackable construction block according to the invention may, typically, be comprised of a body having first and second mutually opposed, spaced surfaces, which are joined around their peripheries by the surface across which the at least one open-ended channel extends.
• the first and second mutually opposed surfaces may form the upper and lower surfaces respectively of the block when viewed in situ.
• These first and second surfaces may be substantially L-shaped, so as to form a substantially L-shaped block.
• the peripheral surfaces may be comprised of six separate surfaces (to form a three-dimensional "L"), the at least one open-ended channel extending over one such surface from the first surface to the second surface. Others of the six surfaces may be provided with other open-ended channels.
• the first and second surfaces of the block may preferably be provided with one or more protrusions and/or recesses, which are adapted to aid stacking of two or more such blocks.
• a surface may be provided with all protrusions (of the same or varying dimensions), all recesses (of the same or varying dimensions), or a combination of protrusions and recesses of the same or varying dimensions.
• the one or more protrusions and/or recesses provided in the first surface may be arranged so as to be mutually complementary with the one or more protrusions and/or recesses provided in the second surface, to aid stacking of two or more such blocks whereby the first surface of one block abuts the second surface of the other block, and the protrusions in the first surface of one block cooperatively mate with the complementary recesses in the second surface of the other block, and vice versa.
• a stackable construction block according to the invention may be provided with one or more internal voids therein. Such a measure would assist in reducing the overall weight of the block and could also reduce the cost per block (as the amount of material needed to manufacture each block may be reduced).
• the one or more internal voids may be provided as extensions of said recesses from the surface into the body of the block. Furthermore, the one or more internal voids may be configured such that, when a block is separated into two block portions, at least one of such voids is exposed thus forming an open-ended channel adapted to receive a block-joining element in the same manner as the pre-existing open-ended channels provided in the block.
• At least one reinforcing element may be provided in association therewith, preferably within the body of the block.
• Suitable reinforcing elements include steel bars, aluminium extrusions and glass-reinforced plastic pultrusions.
• a construction block assembly comprising:
• two or more stackable construction blocks each comprising at least one open- ended channel extending across a surface thereof adapted to receive a block-joining element, provided in stacked form, having their at least one open-ended channels aligned so as to form an extended channel, and
• At least one block-joining element located in said extended channel, thereby maintaining said blocks in stacked form.
• the two or more stackable construction blocks comprised in the assembly are preferably of the type hereinbefore described.
• the at least one block-joining element used to join the two or more stackable construction blocks may preferably comprise an elongate brace, which may for example be a timber brace, or an extruded plastics brace (the plastics material optionally being a recycled plastics material).
• the at least one block-joining element may be fixed into place in the extended channel formed by the stacked blocks by a suitable adhesive, such as a hot-melt adhesive.
• the at least one block-joining element may also be used as a component to which one or more other construction components, e.g. window frames, door frames, etc., may be fastened via suitable fixing means, such as nails, screws, etc.
• At least one sheet of cladding material may be provided so as to obscure the extended channel and the block-joining element located therein.
• the cladding material may be in the form of timber panels, oriented strand boards (OSBs), plywood panels, magnesium silicate boards, calcium silicate boards, and the like.
• OSBs oriented strand boards
• the assembly may have at least one exterior-facing surface and at least one interior facing surface, wherein additional weatherproof cladding may be provided on, so as to finish, said at least one exterior-facing surface.
• the additional weatherproof cladding may be aluminium cladding.
• the additional weatherproof cladding may be used to obscure and conceal a downpipe that may extend from guttering.
• cladding material may be provided on one or both of the exterior surfaces of one or more of the blocks, preferably over the entirety of said surface(s) including and into each of the open-ended channels therein.
• the cladding material may be cast onto said exterior surface(s), preferably on each block in an assembly.
• the at least one block-joining element may be located on an interior surface of the blocks in the assembly to join them together.
• the cladding material may be a castable or otherwise settable material, e.g. limestone aggregate, which is able to provide a stone or stone-effect exterior finish to the assembly.
• an assembly according to the invention may be additionally provided with an integrated heating element on or in the at least one interior-facing surface.
• the integrated heating element may be a radiant heating element, which may be embedded into the at least one interior-facing surface.
• a construction block assembly in accordance with the invention may preferably be assembled in the absence of any kind of cementitious material, such as cement, mortar, etc, located between adjacent stocked construction blocks.
• a building comprising, preferably as a structural member thereof, at least one construction block assembly comprising two or more stackable construction blocks, each comprising at least one open-ended channel extending across a surface thereof adapted to receive a block-joining element, provided in stacked form, having their at least one open-ended channels aligned so as to form an extended channel, and at least one block-joining element located in said extended channel, thereby maintaining said blocks in stacked form.
• the at least one construction block assembly comprised in the building is preferably of the type hereinbefore described.
• the at least one construction block assembly may form a corner pillar or a non-corner pillar of the building.
• the building When used to form a corner pillar of the building, the building may further comprise at least one corner post against which the at least one construction block assembly is abutted and located.
• the building in accordance with the present invention may be in the form of an extension to an existing building. Such extension may be in the form of a conservatory or an orangery, and it may be of a single or multiple storeys.
• the at least one construction block assembly may be constructed above and/or adjacent to a layer of other building material, for example one or more courses of bricks and mortar, and tied thereto with suitable tying means.
• Figure 1 is a perspective view from above of a stackable construction block according to the invention.
• Figure 2 is a plan view from above of the block shown in Figure 1 ;
• Figure 3 is a perspective view from below of the block shown in Figure 1 ;
• Figures 4a and 4b are perspective views of two different separated portions of the block shown in Figure 1 ;
• Figure 5 is a perspective view of an incomplete construction block assembly according to the invention.
• Figure 6 is a perspective view of the completed construction block assembly shown in Figure 5;
• Figure 7 is a perspective view of the construction block assembly of Figure 6 shown in situ during construction of a building as viewed from the exterior;
• Figure 8 is a perspective view of the construction block assembly of Figure 6 shown in situ during construction of a building as viewed from the interior;
• Figure 9 is a view of a building constructed using at least one construction block assembly according to the invention.
• Figures 10a to 10d are plan views of alternative constructions block assemblies that may be used in the building shown in Figure 9;
• Figures 1 1 and 12 are views of the construction block assembly of Figure 6 shown with a further construction component;
• Figure 13 is a perspective view of the construction block assembly shown in situ in Figure 7 with a further construction component, as shown in Figures 1 1 and 12; and Figure 14 is a perspective view of a further alternative stackable construction block according to the invention.
• the stackable construction block 10 shown in Figure 1 to 3 comprises an L-shaped body 1 1 made from a suitably moulded, extruded and/or cut plastics material, such as polystyrene, provided with a number of features.
• Body 1 1 is provided with a plane of symmetry (S) shown in Figure 2.
• block 10 comprises a plurality (being twelve in number) of open-ended channels 12, each adapted in shape and size to receive a block-joining element 51 (shown in Figures 5 and 6).
• open-ended channels 12 are substantially identical to accommodate substantially identical block- joining elements; however one or more of such channels may be (substantially) non- identical to the others to accommodate different block-joining element(s).
• Each open-ended channel 12 extends across an exterior side surface 13a, 13b, 13c, 13d, 13e, 13f of block 10, between upper surface 14a (shown in Figures 1 and 2) and lower surface 14b (shown in Figure 3).
• upper surface 14a shown in Figures 1 and 2
• lower surface 14b shown in Figure 3
• the orientation of block 10 could be inverted such that the position of upper surface 14a and lower surface 14b are switched.
• both configurations are within the scope of the invention. However, for clarity, only the orientation shown will be described in further detail.
• Upper surface 14a of block 10 is provided with a protrusion 15, which is substantially L- shaped to mirror the overall shape of surface 14a, whilst lower surface 14b of block 10 is provided with a recess 16, which is also substantially L-shaped to mirror the overall shape of surface 14b.
• Protrusion 15 is configured so as to intimately fit within recess 16 to aid stacking of two or more such blocks 10. Assuming the provision of identical blocks 10, stacking of said blocks is achieved by abutting the lower surface 14b of a second block 10 with the upper surface 14a of a first block 10, such that the protrusion 15 of the upper surface 14a of the first block cooperatively mates with the complementary recess 16 provided in the lower surface of the second block.
• An assembly 50 of seven stacked construction blocks 10 is shown in more detail in Figure 5.
• protrusion 15 and one complementary recess 16 are shown as being provided in block 10 in Figures 1 to 3, it is of course possible that two or more protrusions could be provided, along with two or more complementary recesses, and that each of the upper 14a and lower 14b surfaces could be provided with both protrusions and recesses. The only criteria being that any protrusion in one surface is provided with a complementary recess in the opposite surface so as to aid stacking of two or more such blocks.
• Block 10 further comprises a number of internal voids 17 within body 1 1 and a cut-out 18 (shown in dashed outline) at the elbow portion 19 of its body 1 1 .
• Voids 17 are elongate and extend from lower surface 14b either: (a) part-way into body 1 1 or (b) all the way through body 1 1 to upper surface 14a.
• Cut-out 18 is also elongate and substantially square in cross-section, so as to accommodate a corner post (not shown), or a downpipe (not shown), which may also have a substantially square cross-section.
• Block 10 may be separable into two, non-identical substantially rectangular block portions, one of which, block portion 10a, is shown in Figure 4a.
• Figure 4b illustrates how block portion 10a can be further reduced in size (by separation along separation line 20 - discussed in further detail below) to form block portion 10b.
• block 10 could be separated into two, substantially identical block portions by separation along the line of symmetry (S), however this has not been illustrated.
• separation lines 20 are provided across upper surface 14a and/or lower surface 14b of body 1 1 , as shown in Figure 3. Separation lines 20 are provided as surface indications, although they could equally be provided as surface indentations.
• Figure 3 shows the presence of two separation lines 20 to enable separation of block 10 into block portions 10a, 10b.
• Cutting along just one separation line 20 enables the formation of a left-handed block portion 10a or a right-handed block portion (not shown), whilst further cutting enables the formation of a further block portion 10b.
• a number of internal voids 17 which were within body 1 1 of block 1 1 are exposed, thus forming further open-ended channels 12a adapted to receive a block joining element.
• Lower surface 14b of block 10 is also provided with a number of grooves 21 which are configured and located to adapt a border 52 (shown in Figures 5 to 8), which will be described in more detail below.
• FIGS 5 to 8 illustrate a construction block assembly 50 comprising seven stackable construction blocks 10 of the type shown in Figures 1 to 3. Although seven blocks are shown, this number is non-limiting. Blocks 10 are provided in stacked form such that their open-ended channels 12 are aligned so as to form extended channels, in each of which block-joining elements, in the form of elongate timber braces 51 , are provided. Block-joining elements 51 are fixed in place in the extended channels by a hot-melt adhesive (not shown). Block-joining elements 51 are provided as the means by which blocks are hold together. For the avoidance of doubt, formation of assembly 50 is achieved in the absence of any kind of cementitious material, such as cement, mortar, etc.
• Border 52 is made from one or more polyvinyl chloride (PVC) panels, which are affixed to block-joining elements 51 , for example using nails, screws or adhesive (not shown), and into grooves 21 provided in lower surface 14b of lowermost block 10.
• PVC polyvinyl chloride
• Located directly above border 52 are six sheets of cladding material 53, in the form of a timber panels, which are also affixed to block-joining elements 51 , for example using nails, screws or adhesive (not shown). Sheets of cladding material 53 are arranged so as to provide an outer skin for assembly 50.
• Border 52 is provided as a physical barrier to minimise (and preferably to prevent) absorption of moisture from below assembly 50 and/or water ingress below weatherproof cladding 93 (shown in Figure 9). Border 52 also provides protection to the lowermost portion of assembly 50 during any transit.
• attachment members 54 Located on the uppermost surface (as shown) of assembly 50 is a pair of attachment members 54, in the form of a pair of timber blocks, which are provided to facilitate attachment of one or more other construction members, e.g. an eaves beam. Attachment members 54 may be fixed to assembly 50 in situ or they may be pre-fixed prior to arrival on site of assembly 50.
• a construction block assembly 50 may be assembled off-site for use in subsequent on-site construction.
• Such off-site construction allows for accurate construction of assemblies 50 and furthermore enables time to be saved on site as compared to the time that would otherwise be required to build a similar sized structure using conventional building materials, for example bricks and mortar.
• Figures 1 1 and 12 show said assembly in conjunction with a further construction component, in the form of a fixing/setting out post 1 10 having a base plate 1 1 1 .
• a post 1 10 is used to aid location of assembly 50 in situ as performing calculations and taking measurements in the foundations of a building can be difficult from an accuracy point of view, and for aiding location of the remainder of a building, e.g. a dwarf wall, using a conventional string line.
• Such a post can also be used as an anchor for the assembly and may aid the structural performance thereof.
• a solid material such as concrete, will ensure proper fixing of the assembly to, e.g. building foundations, as shown in Figure 13.
• Figures 7 and 8 in particular show use of construction block assembly 50 as part of a building 90 (shown in Figure 9).
• Assembly 50 forms part of said building 90 as a structural member thereof, i.e. it is load-bearing.
• assembly 50 forms a corner pillar of the building, and is constructed above two courses 70 of conventional building material, in the form of bricks and mortar, and adjacent to further courses 71 of the same building material.
• a further layer of other building material 72 for example in the form of concrete building blocks (as shown) or in the form of a SIP, is provided above the two courses 70, and inboard of the further courses 71 , of conventional building material, and adjacent to assembly 50, for building insulation purposes.
• a damp-proof membrane (not shown) may be provided over the two courses 70 of building material, so as to lie beneath assembly 50 and courses 71 and 72 of building material.
• Assembly 50 is tied with suitable tying means, for example wall ties (not shown), to courses 71 of building material and/or to layer 72 of other building material to ensure structural stability between these components.
• a gap 74 may be created between assembly 50 and at least the further courses 71 of building material by means of removable spacers (not shown), which may be removed to enable fitting of one or more sheets of weatherproof cladding 93 (shown in Figure 9) to the exterior facing surface(s) of assembly 50, wherein edges of cladding 93 fit so as to form a weather-tight seal into gap 74.
• Figure 13 shows assembly 50 in situ along with fixing / setting out post 1 10 and base plate 1 1 1 .
• Base plate 1 1 1 is located below the two courses 70 of conventional building material.
• Figure 13 also shows the position of other structural components 1 12 in the form of window/door ledges.
• Figure 9 shows a building 90, having an extension 91 thereto in the form of a conservatory, said extension 91 comprising a number of corner pillars 92.
• At least one corner pillar 92 is constructed using a construction block assembly 50 as shown in Figures 5 to 8.
• the exterior-facing surfaces of each corner pillar 92 are finished with weatherproof cladding 93.
• Figures 10a to 10b are plan views of various assemblies 50 that may be used to form corner pillars 92 ( Figures 10a and 10c) and non-corner pillars ( Figures 10b and 10d).
• the assemblies 50 shown in Figures 10a and 10c are built using blocks 10 and reduced-size blocks 10b respectively, whilst those shown in Figures 10b and 10d are built using separable blocks 10a and reduced- size blocks 10b respectively.
• FIG. 14 shows a further alternative stackable construction block 60, which is similar to construction block 10 shown in at least Figure 1 : block 60 comprises an L-shaped body 61 made from a suitably moulded, extruded and/or cut plastics material, such as polystyrene, provided with a number of features.
• block 60 comprises a plurality (being twelve in number) of open-ended channels 62, each adapted in shape and size to receive a block-joining element (not shown).
• the upper surface of block 60 is provided with a protrusion 65, which is substantially L- shaped to mirror the overall shape of the upper surface (whilst the lower surface of block 60 is provided with a recess, which is also substantially L-shaped to mirror the overall shape of the lower surface).
• Protrusion 65 is configured so as to intimately fit within a recess to aid stacking of two or more such blocks 60.
• Block 60 further comprises a cut-out at the elbow portion 63 of its body 61 .
• the cut-out is elongate and substantially square in cross-section, so as to accommodate a corner post 66 (which could alternatively be a downpipe), which may also have a substantially square cross-section. Corner post 66 extends into the two exterior-facing open-ended channels which are located in the cut-out.
• cladding material 67 in the form of a layer of limestone aggregate which has been cast or otherwise affixed thereto.
• Cladding material 67 also extends by means of vanes 68 into four of the exterior-facing open-ended channels 62 of block 60, and over corner post 66.
• a construction block assembly such as that shown in Figures 5 to 8 may comprise a plurality of stackable construction blocks 60, rather than blocks 10, so as to provide an overall effect of stacked stonework (or similar) on the exterior surface thereof.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Building Environments (AREA)
• Conveying And Assembling Of Building Elements In Situ (AREA)

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Citations (7)

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• 2012
  • 2012-05-14 GB GBGB1208358.0A patent/GB201208358D0/en not_active Ceased
• 2013
  • 2013-05-13 WO PCT/GB2013/051224 patent/WO2013171466A1/en active Application Filing
  • 2013-05-13 EP EP13722034.9A patent/EP2867419B1/de active Active

Patent Citations (7)

Non-Patent Citations (1)

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