GB2610405A

GB2610405A - A construction module and a method of forming a construction module

Info

Publication number: GB2610405A
Application number: GB2112527.3A
Authority: GB
Inventors: Lockett Daniel
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-09-02
Filing date: 2021-09-02
Publication date: 2023-03-08
Also published as: GB202112527D0

Abstract

A construction system or module comprises: a plurality of construction blocks, wherein each construction block comprises two outer layers and a middle layer, the outer layers having a first cross section and the middle layer having a second, different cross section. The outer layers each form a tessellating pattern when the construction blocks are placed in a planar arrangement and the middle layer forms a different tessellating pattern. At least some of the blocks have middle layers having projections from one or more sides of the block, and at least some of the blocks have middle layers having recesses on two or more sides of the block, such that when a projection is engaged with a recess, the projection at least substantially fills the recess and the blocks are restricted from relative movement in the direction perpendicular to the plane of the tessellating patterns. Each block may comprise three or more middle layers, at least two middle layers being of the second cross section and another middle layer between the two being of the first cross section, i.e. the same shape as the outer layers. The blocks may comprise two sealing subsets, a first subset having front and rear sealing projections running around the sides of the front and rear layers respectively and a second subset having front and rear sealing grooves running around the sides of the front and rear layers respectively, such that when assembled, the sealing projections of the first subset are received in the sealing grooves of the second subset. Corner, edge and wall connection blocks may also be included in the system. The layers may be integrally formed or may be formed separately and fixed together.

Description

TITLE

A construction module and a method of forming a construction module.

TECHNOLOGICAL FIELD

Embodiments of the present disclosure relate to a construction module and a method of forming a construction module. Some relate to a construction module and a method of forming a construction module for use in constructing buildings.

BACKGROUND

Various methods of construction are previously known. For example, a construction module made of bricks may be provided where laying the bricks in a certain arrangement can be used to form at least part of a building. The disadvantage with bricklaying is that it requires grouting to fix the bricks together and arranging the bricks in the correct arrangement is not straightforward, particularly for a novice.

BRIEF SUMMARY

According to various, but not necessarily all, embodiments there is provided a construction module, comprising: a plurality of construction blocks, wherein each construction block comprises a front layer, a rear layer and a middle layer; wherein the front layer has a cross section of a first two-dimensional shape; wherein the rear layer has a cross section of the first two-dimensional shape; wherein the middle layer has a cross section of a second two-dimensional shape, different to the first two-dimensional shape; wherein the front layers form a tessellating pattern and the rear layers form a tessellating pattern when the construction blocks are placed in a planar arrangement; wherein at least some of the construction blocks have middle layers which provide projections which protrude from one or more sides of the construction block, wherein at least some of construction blocks have middle layers which provide recesses on two or more sides of the construction block; wherein the recesses are configured to engage with the projections such that when a projection is engaged with a recess, the projection at least substantially fills the recess it is engaged with; wherein when a projection of one construction block engages with a recess of another construction block, the two construction blocks are restricted from relative movement in the direction perpendicular to the plane of the tessellating pattern.

In some, but not necessarily all, examples, a first subset of the construction blocks comprise the recesses only and a second subset of the construction blocks comprises the projections only.

In some, but not necessarily all, examples, each construction block comprises at least one of the projections and at least one of the recesses.

In some, but not necessarily all, examples, each construction block that comprises projections has at least two projections orientated in different directions.

In some, but not necessarily all, examples, all of the construction blocks are the substantially the same shape.

In some, but not necessarily all, examples, all of the construction blocks have the same front layer and rear layer.

In some, but not necessarily all, examples, a first group of the construction blocks are substantially the same shape, and a second group of the construction blocks, different to the first group, are substantially the same shape.

In some, but not necessarily all, examples, each construction block has at least one side comprising multiple projections or multiple recesses.

In some, but not necessarily all, examples, each construction block has at least one side comprising a projection and a recess.

In some, but not necessarily all, examples, each construction block comprises at least two additional middle layers, wherein one of the additional middle layers has a cross section of the first two-dimensional shape, and another of the additional layers has a cross section of the second two-dimensional shape.

In some, but not necessarily all, examples, each projection has a hole, and each recess is located between a front layer portion with a hole and a rear layer portion with a hole, wherein the front layer portion hole, rear layer portion hole and the hole in a projection become aligned when the projection is inserted into the recess, wherein when the hole are aligned, the construction module enables a locking member to be inserted through the aligned holes.

In some, but not necessarily all, examples, the front layer and/or rear layer of one or more of the construction blocks has edges which are chamfered and/or rounded.

In some, but not necessarily all, examples, the projections have chamfered and/or rounded edges, and the recesses are correspondingly chamfered and/or rounded.

In some, but not necessarily all, examples, the front layer and rear layer comprise angled faces.

In some, but not necessarily all, examples, the layers of each construction module are integral.

In some, but not necessarily all, examples, the layers of each construction block are distinct and are configured to be attached together by attachment means to form the construction block.

In some, but not necessarily all, examples, the plurality of construction blocks comprise a first sealing subset and a second sealing subset, wherein the construction blocks in the first sealing subset comprise a front sealing projection and a rear sealing projection, wherein the front sealing projection runs around the sides of the construction block between the face of the front layer and the middle layer, wherein the rear sealing projection runs around the sides of the construction block between the face of the rear layer and the middle layer; wherein the construction blocks in the second sealing subset comprise a front sealing groove and a rear sealing groove, wherein the front sealing groove runs around the sides of the construction block between the face of the front layer and the middle layer, wherein the rear sealing groove runs around the sides of the construction block between the face of the rear layer and the middle layer; wherein when a construction block from the first sealing subset and the second sealing subset are brought together so that a projection from one of the blocks engages with a recess on the other block, the front sealing projection enters the front sealing groove and the rear sealing projection enters the rear sealing groove.

In some, but not necessarily all, examples, the construction module comprises one or more corner blocks, wherein the one or more corner blocks comprise a column and two connecting sections, wherein each connecting section is connected to the column, wherein the connecting sections comprise projections and/or recesses which engage with corresponding projections and/or recesses on the construction blocks, to enable construction of two planar arrangements of the construction blocks, which are angled relative to each other due to the two connecting sections being angled relative to oner another; wherein the column comprises a projection or recess on the top of the column for connecting to a corresponding projection or recess on the bottom of a column of another corner block placed above the corner block and wherein the column comprises a projection or recess on the bottom of the column for connecting to a corresponding projection or recess on the top of a column of another corner block placed below the corner block.

In some, but not necessarily all, examples, the construction module comprises one or more connecting blocks, wherein each connecting block comprises a column and three connecting sections, wherein each connecting section is connected to the column, wherein the connecting sections comprise projections and/or recesses which engage with corresponding projections and/or recesses on the construction blocks, to enable construction of three planar arrangements of the construction blocks, wherein two of the planar arrangements are parallel and the third planar arrangement is perpendicular to the other two planar arrangements, due to the arrangement of the three connecting sections; wherein the column comprises a projection or recess on the top of the column for connecting to a corresponding projection or recess on the bottom of a column of another connecting block placed above the connecting block and wherein the column comprises a projection or recess on the bottom of the column for connecting to a corresponding projection or recess on the top of a column of another connecting block placed below the connecting block.

In some, but not necessarily all, examples, the construction module comprises one or more connecting blocks, wherein each connecting block comprises a column and four connecting sections, wherein each connecting section is connected to the column, wherein the connecting sections comprise projections and/or recesses which engage with corresponding projections and/or recesses on the construction blocks, to enable construction of four planar arrangements of the construction blocks, wherein two of the planar arrangements are parallel and the other two planar arrangements are parallel, wherein the two pairs of planar arrangements are perpendicular to each other, due to the arrangement of the four connecting sections; wherein the column comprises a projection or recess on the top of the column for connecting to a corresponding projection or recess on the bottom of a column of another connecting block placed above the connecting block and wherein the column comprises a projection or recess on the bottom of the column for connecting to a corresponding projection or recess on the top of a column of another connecting block placed below the connecting block.

In some, but not necessarily all, examples, the construction module comprises one or more end blocks, wherein each end block comprises a column and one connecting section, wherein the connecting section is connected to the column, wherein the connecting section comprises at least one projection or recess which engages with corresponding projections and/or recesses on the construction blocks, to enable construction of a planar arrangement of the construction blocks with an end; wherein the column comprises a projection or recess on the top of the column for connecting to a corresponding projection or recess on the bottom of a column of another connecting block placed above the connecting block and wherein the column comprises a projection or recess on the bottom of the column for connecting to a corresponding projection or recess on the top of a column of another connecting block placed below the connecting block.

According to various, but not necessarily all, embodiments there is provided a method of forming a construction module, comprising: forming a front layer, the front layer having a cross section of a first two-dimensional shape; forming a rear layer, the rear layer having a cross section of the first two-dimensional shape; forming a middle layer, the middle layer having a cross section of a second two-dimensional shape; forming a construction block from the front layer, rear layer and the middle layer between the front layer and the rear layer; forming multiple such construction blocks; wherein the front layers form a tessellating pattern and the rear layers form a tessellating pattern when the construction blocks are placed in a planar arrangement; wherein at least some of the construction blocks have middle layers which provide projections which protrude from one or more sides of the construction block, wherein at least some of construction blocks have middle layers which provide recesses on one or more sides of the construction block; wherein the recesses are configured to engage with the projections such that when a projection is engaged with a recess, the projection at least substantially fills the recess it is engaged with; wherein when a projection of one construction block engages with a recess of another construction block, the two construction blocks are restricted from relative movement in the direction perpendicular to the plane of the tessellating pattern.

In some, but not necessarily all, examples, forming the middle layer comprises taking a layer with a cross section of the first two-dimensional shape and either adding additional parts to the layer or removing parts of the layer.

In some, but not necessarily all, examples, the adding comprises arranging multiple identical circle sectors in an arrangement, and superimposing the arrangement and the layer, and wherein the removing comprises arranging multiple identical circle sectors in a second arrangement, arranging the layer to overlie the second arrangement or vice versa, and removing the parts of the layer which overlie or are overlaid by the circle sectors.

In some, but not necessarily all, examples, forming a construction block comprises pouring a settable liquid into a mold, wherein the mold provides the construction block with the front layer, middle layer and rear layer integrally formed together.

In some, but not necessarily all, examples, the mold comprises sections which provide angled faces for the front and rear layers.

In some, but not necessarily all, examples, forming a construction block from the front layer, rear layer and the middle layer between the front layer and the rear layer comprises attaching the layers together by attachment means to form the construction block.

In some, but not necessarily all, examples, the method further comprises forming at least two additional middle layers for each construction block, wherein one of the additional middle layers has a cross section of the first two-dimensional shape, and another of the additional layers has a cross section of the second two-dimensional shape.

In some, but not necessarily all, examples, the method comprises forming multiple projections and/or recesses on each middle layer.

According to various, but not necessarily all, embodiments there is provided examples as claimed in the appended claims.

BRIEF DESCRIPTION

Some examples will now be described with reference to the accompanying drawings in which: FIG. 1A shows an example of the subject matter described herein; FIG. 1B shows another example of the subject matter described herein; FIG. 1C shows another example of the subject matter described herein; FIG. 2A shows another example of the subject matter described herein; FIG. 2B shows another example of the subject matter described herein; FIG. 3A shows another example of the subject matter described herein; FIG. 3B shows another example of the subject matter described herein; FIG. 4 shows another example of the subject matter described herein; FIG. 5A shows another example of the subject matter described herein; FIG. 5B shows another example of the subject matter described herein; FIG. 6A shows another example of the subject matter described herein; FIG. 63 shows another example of the subject matter described herein; FIG. 6C shows another example of the subject matter described herein; FIG. 6D shows another example of the subject matter described herein; FIG. 7 shows another example of the subject matter described herein; FIG. 8A shows another example of the subject matter described herein; FIG. 8B shows another example of the subject matter described herein; FIG. 9A shows another example of the subject matter described herein; FIG. 93 shows another example of the subject matter described herein; FIG. 10A shows another example of the subject matter described herein; FIG. 10B shows another example of the subject matter described herein; FIG. 11 shows another example of the subject matter described herein; FIG. 12 shows another example of the subject matter described herein; FIG. 13A shows another example of the subject matter described herein; FIG. 133 shows another example of the subject matter described herein; FIG. 13C shows another example of the subject matter described herein; and FIG. 13D shows another example of the subject matter described herein; FIG. 14A shows another example of the subject matter described herein; FIG. 14B shows another example of the subject matter described herein; FIG. 14C shows another example of the subject matter described herein; FIG. 14D shows another example of the subject matter described herein; FIG. 15A shows another example of the subject matter described herein; FIG. 153 shows another example of the subject matter described herein; FIG. 15C shows another example of the subject matter described herein; FIG. 15D shows another example of the subject matter described herein; FIG. 16A shows another example of the subject matter described herein; FIG. 163 shows another example of the subject matter described herein; FIG. 16C shows another example of the subject matter described herein; and FIG. 16D shows another example of the subject matter described herein

DETAILED DESCRIPTION

FIGS. 1A, 1B and 1C illustrate an example construction module 100. The construction module 100 comprises a plurality of construction blocks 110. Each construction block comprises a front layer 111, a middle layer 112 and a rear layer 113. The front layer 111 has a cross-section of a first two-dimensional shape. The rear layer 113 also has a cross-section of the first two-dimensional shape. For example, the construction block shown in FIG.1C has a front layer and rear layer with a cross-section of a circle. The middle layer 112 has a cross-section of a second two-dimensional shape, which is different to the first two-dimensional shape. For example, the middle layer in FIG. 10 has a cross-section of a plus sign with rounded edges at the tips of the plus sign.

As illustrated in FIG. 1A the front layers 111 form a tessellating pattern and the rear layers 113 form a tessellating pattern when the construction blocks 110 are placed in a planer arrangement. In this context a tessellating pattern means a pattern which is a repeating pattern.

At least some of the construction blocks 110 have middle layers 112 which provide projections 120 which protrude from one or more sides of the construction block 110. At least some of the construction blocks 110 have middle layers 112 which provide recesses 130 on one or more sides of the construction block 110.

The recesses 130 are configured to engage with the projections 120 so that when a projection 120 is engaged with a recess 130, the projection 120 at least substantially fills the recess 130 it is engaged with. In this example, at least substantially fills means that there are no significant air gaps or cavities when the projection 120 is engaged with the recess 130 and the gaps that form are only due to the gaps occurring due to the boundaries between the projection 120 and the recess 130.

When a projection 120 of one construction block 110 engages with a recess 130 of another construction block 110, the two construction blocks are restricted from relative movement in the direction perpendicular to the plane of the tessellating pattern.

In the example of FIGS. 1A, 1B and 10 there is a first group 140 of the construction blocks which are substantially the same shape, and a second group 150 of the construction blocks, different to the first group, which is substantially the same shape.

FIGS. 2A, 2B illustrate two different views of an example construction block 110 of another example construction module 100. In the example of FIG. 2, each construction block 110 comprises two projections 120 and two recesses 130. It can be seen that the projections on each construction block 110 are orientated in different directions.

This enables the construction block to be reversible so that it can be used either way in the construction module. In the example of FIG. 2 all of the construction blocks 110 are substantially the same shape.

FIGS. 3A and 3B illustrate example construction blocks 110 of another example construction module 100. In this example a first subset 310 of the construction blocks comprises the projections only and a second subset 320 of the construction blocks comprises the recesses only. In this example, all of the construction blocks 110 have the same front layer 111 and rear layer 113. The middle layers 112 of the first subset 310 and the second subset 320 are different.

FIG. 4 illustrates an example construction block 110 of another example construction module 100. In this example, the construction block 110 has at least one side comprising multiple projections 120. In this example each side has multiple projections 120. In another example the construction block comprises sides which comprise multiple recesses. In other examples, at least one of the sides of the construction block comprises at least one projection as previously shown and at least one other side comprises at least one recess as previously shown. In other examples, a side of the construction block may have at least one projection and at least one recess.

FIGS. 5A, 5B illustrate two views of another example construction block 110 of another example construction module 100. In this example each construction block comprises two additional middle layers 510, 520. One of the additional middle layers 520 has a cross-section of the first two-dimensional shape, the same as the front layer and the rear layer and another of the additional layers 510 has a cross-section of the second two-dimensional shape, which is the same shape as the other middle layer. This example shows two additional middle layers. In other examples more than two additional middle layers are provided.

FIGS. 6A, 6B, 60, 6D illustrate example construction blocks 110 of another example construction module 100. In this example, each projection 120 has a hole 610 and each recess 130 has a front layer portion with a hole 620 and a rear layer portion with a hole 630. When a projection is inserted into a recess the projection hole 610 and the holes 620, 630 proximate to the recess become aligned so that this enables a locking member 640 to be inserted through the aligned holes.

FIGS. 6A to 6D illustrates the process of aligning the holes and inserting the locking member 640 through the holes. By providing the locking member 640 through the holes this provides further securing of the construction blocks together. The locking member 640 may also be provided to provide a tight friction fit which may need to be inserted using a hammer so that it resists removal to provide strong securement of the construction blocks together.

FIG. 7 shows another example construction block 110 of another example construction module 100. In this example, the front layer and the rear layer have had their edges chamfered as well as the projections. The recesses on corresponding construction blocks within this construction module 100 will also have at least correspondingly chamfered recesses. In some examples, only front layers are chamfered or rear layers are chamfered. In other examples, only the projections and recesses are chamfered.

In other examples, only front and/or rear layers are chamfered and not the projections and recesses. In other examples, instead of chamfering the edges of the front layers, rear layers, projections and recesses, they are rounded instead.

FIG. 8A and FIG. 8B illustrate example construction blocks 110 from another example construction module 100. In this example, the front and rear layers of the construction blocks 100 have angled faces 810, 820 and tapered projections 120 and tapered recesses 130. The angled faces 810, 820 enable easier release from molds. In this example, the projections 120 and recesses 130 are tapered, in that the projections 120 taper towards their tips and the recesses 130 are correspondingly profiled to taper towards the bottom of the recess 130. The tapering of the projections 120 and recesses 130 enables easier release from the molds.

In the examples illustrated above, the layers of the construction blocks 110 are integral.

That is, there is no distinct boundary between the different layers. This is because in these examples the layers have been formed at the same time, i.e. in a mold as illustrated below in FIGS 13A to 13D.

FIGS. 9A and 9B illustrate example construction blocks 110 of another construction module 100 where the layers of each construction block are distinct. In FIGS. 9A and 9B the construction blocks are disassembled. The layers of each construction block are attached together by attachment means to form the construction block. For example, the front layer may be glued to the middle layer and the middle layer may be glued to the rear layer. Any of the examples illustrated where the layers are integrally formed can also be formed by forming distinct layers and then attaching the separate layers together to form the construction block.

FIGS. 10A and 10B illustrate example construction blocks 110 of another example construction module 100. In this example, a first sealing subset 1010 comprises construction blocks which have a front sealing projection 1011 and a rear sealing projection 1012. The front sealing projection 1011 runs along the sides of the construction block between the face of the front layer and the middle layer. The rear sealing projection 1012 runs along the sides of the construction block between the face of the rear layer and the middle layer.

FIG. 10B illustrates a construction block 110 of a second sealing subset 1020 and comprises a front sealing groove 1021 and a rear sealing groove 1022. The front sealing groove 1021 runs around the sides of the construction block between the face of the front layer and the middle layer. The rear sealing groove 1022 runs around the sides of the construction block between the face of the rear layer and the middle layer.

When a construction block 110 from the first sealing subset 1010 and the second sealing subset 1020 are brought together so that a projection 120 on one block engages with a recess 130 of the other block, the front sealing projection enters the front sealing groove and the rear sealing projection enters the rear sealing groove.

By providing the sealing projections and the sealing grooves which engage each other this provides more reliable sealing between the construction blocks which advantageously will further prevent relative movement of the blocks and also prevent ingress of water in the situation where the construction module is used in a building.

FIG. 11 illustrates an example method 1100 of forming a construction module. The method 1100 comprises: As a first block 1110, forming a front layer, the front layer having a cross-section of a first two-dimensional shape.

As a second block 1120, forming a rear layer, the rear layer having a cross-section of the first two-dimensional shape.

As a third block 1130, forming a middle layer, the middle layer having a cross-section of a second two-dimensional shape.

As a fourth block 1140, forming a construction block from the front layer, rear layer and the middle layer between the front layer and the rear layer.

As a fifth block 1150, forming multiple such construction blocks.

In the method illustrated above, the front layers form a tessellating pattern and the rear layers form a tessellating pattern when the construction blocks are placed in a planer arrangement. At least some of the construction blocks have middle layers which provide projections which protrude from one or more sides of the construction block. At least some of the construction blocks have middle layers which provide recesses on one or more sides of the construction block. The recesses are configured to engage with the projections such that when a projection is engaged with a recess, the projection at least substantially fills the recess it is engaged with. When a projection of one construction block engages with the recess of another construction block, the two construction blocks are restricted from relative movement in the direction perpendicular to the plane of the tessellating pattern.

In some examples, the forming of the construction block from the front layer, rear layer and the middle layer between the front layer and the rear layer comprises attaching the layers together by attachment means to form the construction block.

In some examples, the method further comprises forming at least two additional middle layers for each construction block. One of the additional middle layers is a cross-section of the first two-dimensional shape, and another of the additional layers has a cross-section of the second two-dimensional shape.

In some examples, the method comprises forming multiple projections and/or recesses on each middle layer.

FIG. 12 is a schematic diagram illustrating how middle layers of different construction blocks can be formed with corresponding projections and recesses and how these middle layers are then combined with front layers and rear layers to form the construction blocks. In a first block 1210, forming a middle layer of a construction block comprises taking a layer 1200 with a cross-section of the first two-dimensional shape and removing parts of the layer 1200 to form the middle layer 112. The removing comprises arranging multiple identical circle sectors 1201 in a first arrangement 1202.

The layer 1200 and the first arrangement are overlaid, one above the other and the parts of the layer which overlay or are overlaid by the circle sectors are removed from the layer 1200.

In a second block 1220, forming a middle layer of a construction block comprises taking a layer 1203 which has a cross-section of the first two-dimensional shape and adding additional parts to the layer. The adding comprises arranging multiple identical circle sectors 1201, those being the same as the sectors used in block 1210 and arranging the multiple identical circle sectors in a second arrangement 1204. Then the second arrangement and the layer 1203 are superimposed and combined to form a middle layer 112.

To create the middle layers 112 of the steps 1210 and 1220, the method may comprise either designing a mold to match the shape of the superimposed shape or by forming a template from the superimposed shape to then cut the middle layer from a new block of material to form a distinct middle layer.

As a third block 1230, the first middle layer 112 is added with a front layer 111 and rear layer 113, only one of which is visible in FIG. 12, and this provides a first construction block 110 In a further block 1240, the second middle layer 112 is added with a front layer 111 and a rear layer 113, only one of which is visible in FIG. 12, forming a second construction block 110.

In a fifth block 1250, the first construction block 110 and the second construction block 110 are combined by inserting the projection of the second construction block 110 into the recess of the first construction block 110, forming a construction module 100.

FIGS. 13A, 13B, 130, 13D illustrate an example of how to form a construction block using method 1100. In this example blocks 1110, 1120 and 1130, which are forming the front layer, middle layer and rear layer are done at the same time and integrally by pouring a settable liquid into a mold 1300. In this example, the mold comprises sections 1310, 1320, 1330 which connect together for example by mold locking members 1340 as illustrated in FIG. 130. The settable liquid may be poured into the mold as illustrated in FIG. 130 and after the sections of the mold are removed and the settable liquid has set, a construction block 110 has been formed as shown in FIG. 13D.

FIGS. 14A and 14B illustrate example construction blocks 110 of another example construction module 100. In this example a first corner block subset 1410 of the construction blocks comprises the projections 120 only and a second corner block subset 1420 of the construction blocks comprises the recesses 130 only. In other examples, corner blocks may have at least one projection and at least one recess.

Example construction blocks correspond to form a tessellating pattern with earlier discussed subsets 310 and 320 as illustrated in FIGS 3A and 3B.

FIGS. 140 and 14D illustrate example construction blocks 110 where the sections of each construction block are distinct. In FIGS. 140 and 14D corner block subsets 1410 and 1420 are disassembled into pillar sections 1411,1421 and connecting sections 1412, 1413, 1422, 1423. The pillar sections have four faces which correspond to a face on the connecting sections whereby multiple or single connecting sections can be attached to the pillar sections to create new perpendicular planes of construction i.e. as illustrated below in FIGS 16A to 16D.

The pillar sections and connecting sections are attached together by attachment means to form the construction block. For example, the connecting sections may be glued to the pillar sections. Any of the examples illustrated where the sections are integrally formed can also be formed by forming distinct sections and then attaching the separate sections together to form the construction block.

FIGS. 15A to 15D illustrate example construction blocks 110 of another example construction module 100. FIGS 15A and 15B illustrate the projections 120 of corner block subset 1410 and the recesses 130 of construction block subset 320 engaged to form a tessellating pattern with two perpendicular planes of construction.

FIG. 15C and 15D illustrate the projections 120 of corner block subset 1410 and construction block subset 310 engaged with the recesses 130 of corner block subset 1420 and construction block subset 320 to form a tessellating pattern with two perpendicular planes of construction and two layers of construction. In this example, the corner block subset 1410 forms a third group 160 of construction blocks which are substantially the same shape and the corner block subset 1420 forms a fourth group 170 of construction blocks which are substantially the same shape.

FIG. 16A to 16D illustrate example construction blocks 100 of another example construction module 100. FIG. 16A illustrates example corner block 1610 which comprises of a single connecting section engaged with construction block subsets 320 and 310 to form a tessellating pattern with one plane of construction.

FIG. 16B illustrates example corner block 1620 which comprises of two connecting sections engaged with construction block subsets 320 and 310 to form a tessellating pattern with two planes of construction.

FIG. 16C illustrates example corner block 1630 which comprises of three connecting sections engaged with construction block subsets 320 and 310 to form a tessellating pattern with three planes of construction.

FIG. 160 illustrates example corner block 1640 which comprises of four connecting sections engaged with construction block subsets 320 and 310 to form a tessellating pattern with four planes of construction.

In some examples the mold comprises end sections which fit over the top and bottom of the mold which then provide angled faces on the front and rear layers of the construction block. By providing angled mold end sections which provide angled faces on the front and rear layers this makes it easier to remove the mold compared to when using a flat top and flat bottom end sections.

In the examples illustrated, various example construction modules have been illustrated. By forming a tessellating pattern made out of either one type of construction block or two types of a construction block it is easy for an end user to understand how the blocks will fit together and they will be able to easily fit the blocks together due to the corresponding projections and recesses which enable the construction blocks to fit together without relative movement. This therefore provides a construction module with the capability of providing a rigid construction in a straightforward manner without the need for expertise in construction.

A variety of construction modules can be used with different shaped construction blocks. Methods illustrated herein show that many different types of construction modules may be formed by taking one shape which is the same shape as the front layer and rear layer and either adding or subtracting identical circular sectors from the first shape to produce middle layers which have correspondingly shaped projections and recesses The length and width of the construction blocks which form the tessellating pattern compared to their depth means that for a given thickness of a construction a relatively high construction can be made with fewer blocks than for example conventional bricks.

Each construction module may be made with a maximum of two molds to provide the two different constructions blocks and in some examples only one mold is required. In other examples, the construction modules can be made by making the separate layers out of any material including wood, plastic or other material. As the shapes making up the construction modules are straightforward it would be easy for someone with not a lot of experience and without sophisticated machinery to make the different layers of each construction block and attach them together to form construction blocks and provide the construction module.

In some examples the construction blocks can be made using injection molding. In some examples the construction blocks can be made using injection compression molding.

The construction blocks can be made from recycled plastic by melting the plastic and using it for molding.

The example construction modules described herein are modules which can form a part of a construction. For example, multiple construction modules can be used to form constructions such as a building, a wall, a set of interconnected walls or another construction. In some examples, the desired final construction may be made of one construction module, and in such examples, there may be the option to expand or change the construction by adding additional construction modules.

The blocks illustrated in the FIGS 11 and 12 may represent steps in a method and/or sections of code in the computer program. The illustration of a particular order to the blocks does not necessarily imply that there is a required or preferred order for the blocks and the order and arrangement of the block may be varied. Furthermore, it may be possible for some blocks to be omitted.

Where a structural feature has been described, it may be replaced by means for performing one or more of the functions of the structural feature whether that function or those functions are explicitly or implicitly described.

The term 'comprise' is used in this document with an inclusive not an exclusive meaning. That is any reference to X comprising Y indicates that X may comprise only one Y or may comprise more than one Y. If it is intended to use 'comprise' with an exclusive meaning then it will be made clear in the context by referring to "comprising only one.." or by using "consisting".

In this description, reference has been made to various examples. The description of features or functions in relation to an example indicates that those features or functions are present in that example. The use of the term 'example' or 'for example' or 'can' or 'may' in the text denotes, whether explicitly stated or not, that such features or functions are present in at least the described example, whether described as an example or not, and that they can be, but are not necessarily, present in some of or all other examples. Thus 'example', 'for example', 'can' or 'may' refers to a particular instance in a class of examples. A property of the instance can be a property of only that instance or a property of the class or a property of a sub-class of the class that includes some but not all of the instances in the class. It is therefore implicitly disclosed that a feature described with reference to one example but not with reference to another example, can where possible be used in that other example as part of a working combination but does not necessarily have to be used in that other example.

Although examples have been described in the preceding paragraphs with reference to various examples, it should be appreciated that modifications to the examples given can be made without departing from the scope of the claims.

Features described in the preceding description may be used in combinations other than the combinations explicitly described above.

Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not.

Although features have been described with reference to certain examples, those features may also be present in other examples whether described or not.

The term 'a' or 'the' is used in this document with an inclusive not an exclusive meaning. That is any reference to X comprising a/the Y indicates that X may comprise only one Y or may comprise more than one Y unless the context clearly indicates the contrary. If it is intended to use 'a' or 'the' with an exclusive meaning then it will be made clear in the context. In some circumstances the use of 'at least one' or 'one or more' may be used to emphasis an inclusive meaning but the absence of these terms should not be taken to infer any exclusive meaning.

The presence of a feature (or combination of features) in a claim is a reference to that feature or (combination of features) itself and also to features that achieve substantially the same technical effect (equivalent features). The equivalent features include, for example, features that are variants and achieve substantially the same result in substantially the same way. The equivalent features include, for example, features that perform substantially the same function, in substantially the same way to achieve substantially the same result.

In this description, reference has been made to various examples using adjectives or adjectival phrases to describe characteristics of the examples. Such a description of a characteristic in relation to an example indicates that the characteristic is present in some examples exactly as described and is present in other examples substantially as described.

Whilst endeavoring in the foregoing specification to draw attention to those features believed to be of importance it should be understood that the Applicant may seek protection via the claims in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not emphasis has been placed thereon.

I/we claim:

Claims

CLAIMS1. A construction module, comprising: a plurality of construction blocks, wherein each construction block comprises a front layer, a rear layer and a middle layer; wherein the front layer has a cross section of a first two-dimensional shape; wherein the rear layer has a cross section of the first two-dimensional shape; wherein the middle layer has a cross section of a second two-dimensional shape, different to the first two-dimensional shape; wherein the front layers form a tessellating pattern and the rear layers form a tessellating pattern when the construction blocks are placed in a planar arrangement; wherein at least some of the construction blocks have middle layers which provide projections which protrude from one or more sides of the construction block, wherein at least some of the construction blocks have middle layers which provide recesses on two or more sides of the construction block wherein the recesses are configured to engage with the projections such that when a projection is engaged with a recess, the projection at least substantially fills the recess it is engaged with; wherein when a projection of one construction block engages with a recess of another construction block, the two construction blocks are restricted from relative movement in the direction perpendicular to the plane of the tessellating pattern.
2. A construction module as claimed in claim 1, wherein a first subset of the construction blocks comprise the recesses only and a second subset of the construction blocks comprises the projections only.
3. A construction module as claimed in claim 1, wherein each construction block comprises at least one of the projections and at least one of the recesses.
4. A construction module as claimed in any preceding claim, wherein each construction block that comprises projections has at least two projections orientated in different directions.
5. A construction module as claimed in claim 1 or claim 3, or claim 4 when dependent on either of claim 1 or claim 3, wherein all of the construction blocks are substantially the same shape.
6. A construction module as claimed in any of claims 1 to 4, wherein all of the construction blocks have the same front layer and rear layer.
7. A construction module as claimed in any of claims 1 to 4, wherein a first group of the construction blocks are substantially the same shape, and a second group of the construction blocks, different to the first group, are substantially the same shape.
8. A construction module as claimed in any preceding claim, wherein each construction block has at least one side comprising multiple projections or multiple recesses.
9. A construction module as claimed in any preceding claim, wherein each construction block has at least one side comprising a projection and a recess.
10. A construction module as claimed in any preceding, wherein each construction block comprises at least two additional middle layers, wherein one of the additional middle layers has a cross section of the first two-dimensional shape, and another of the additional layers has a cross section of the second two-dimensional shape.
11. A construction module as claimed in any preceding claim, wherein each projection has a hole, and each recess is located between a front layer portion with a hole and a rear layer portion with a hole, wherein the front layer portion hole, rear layer portion hole and the hole in a projection become aligned when the projection is inserted into the recess, wherein when the hole are aligned, the construction module enables a locking member to be inserted through the aligned holes.
12. A construction module as claimed in any preceding claim, wherein the front layer and/or rear layer of one or more of the construction blocks has edges which are chamfered and/or rounded.
13. A construction module as claimed in any preceding claim, wherein the projections have chamfered and/or rounded edges, and the recesses are correspondingly chamfered and/or rounded.
14. A construction module as claimed in any preceding claim, wherein the front layer and rear layer comprise angled faces.
15. A construction module as claimed in any preceding claim, wherein the layers of each construction module are integral.
16. A construction module as claimed in any of claims 1 to 14, wherein the layers of each construction block are distinct and are configured to be attached together by attachment means to form the construction block.
17. A construction module as claimed in any preceding claim, wherein the plurality of construction blocks comprise a first sealing subset and a second sealing subset, wherein the construction blocks in the first sealing subset comprise a front sealing projection and a rear sealing projection, wherein the front sealing projection runs around the sides of the construction block between the face of the front layer and the middle layer, wherein the rear sealing projection runs around the sides of the construction block between the face of the rear layer and the middle layer; wherein the construction blocks in the second sealing subset comprise a front sealing groove and a rear sealing groove, wherein the front sealing groove runs around the sides of the construction block between the face of the front layer and the middle layer, wherein the rear sealing groove runs around the sides of the construction block between the face of the rear layer and the middle layer; wherein when a construction block from the first sealing subset and the second sealing subset are brought together so that a projection from one of the blocks engages with a recess on the other block, the front sealing projection enters the front sealing groove and the rear sealing projection enters the rear sealing groove.
18. A construction module as claimed in any preceding claim, wherein the construction module comprises one or more corner blocks, wherein the one or more corner blocks comprise a column and two connecting sections, wherein each connecting section is connected to the column, wherein the connecting sections comprise projections and/or recesses which engage with corresponding projections and/or recesses on the construction blocks, to enable construction of two planar arrangements of the construction blocks, which are angled relative to each other due to the two connecting sections being angled relative to oner another; wherein the column comprises a projection or recess on the top of the column for connecting to a corresponding projection or recess on the bottom of a column of another corner block placed above the corner block and wherein the column comprises a projection or recess on the bottom of the column for connecting to a corresponding projection or recess on the top of a column of another corner block placed below the corner block.
19. A construction module as claimed in claim 1, wherein the construction module comprises one or more connecting blocks, wherein each connecting block comprises a column and three connecting sections, wherein each connecting section is connected to the column, wherein the connecting sections comprise projections and/or recesses which engage with corresponding projections and/or recesses on the construction blocks, to enable construction of three planar arrangements of the construction blocks, wherein two of the planar arrangements are parallel and the third planar arrangement is perpendicular to the other two planar arrangements, due to the arrangement of the three connecting sections; wherein the column comprises a projection or recess on the top of the column for connecting to a corresponding projection or recess on the bottom of a column of another connecting block placed above the connecting block and wherein the column comprises a projection or recess on the bottom of the column for connecting to a corresponding projection or recess on the top of a column of another connecting block placed below the connecting block.
20. A construction module as claimed in claim 1, wherein the construction module comprises one or more connecting blocks, wherein each connecting block comprises a column and four connecting sections, wherein each connecting section is connected to the column, wherein the connecting sections comprise projections and/or recesses which engage with corresponding projections and/or recesses on the construction blocks, to enable construction of four planar arrangements of the construction blocks, wherein two of the planar arrangements are parallel and the other two planar arrangements are parallel, wherein the two pairs of planar arrangements are perpendicular to each other, due to the arrangement of the four connecting sections; wherein the column comprises a projection or recess on the top of the column for connecting to a corresponding projection or recess on the bottom of a column of another connecting block placed above the connecting block and wherein the column comprises a projection or recess on the bottom of the column for connecting to a corresponding projection or recess on the top of a column of another connecting block placed below the connecting block.
21. A construction module as claimed in claim 1, wherein the construction module comprises one or more end blocks, wherein each end block comprises a column and one connecting section, wherein the connecting section is connected to the column, wherein the connecting section comprises at least one projection or recess which engages with corresponding projections and/or recesses on the construction blocks, to enable construction of a planar arrangement of the construction blocks with an end; wherein the column comprises a projection or recess on the top of the column for connecting to a corresponding projection or recess on the bottom of a column of another connecting block placed above the connecting block and wherein the column comprises a projection or recess on the bottom of the column for connecting to a corresponding projection or recess on the top of a column of another connecting block placed below the connecting block.
22. A method of forming a construction module, comprising: forming a front layer, the front layer having a cross section of a first two-dimensional shape; forming a rear layer, the rear layer having a cross section of the first two-dimensional shape; forming a middle layer, the middle layer having a cross section of a second two-dimensional shape; forming a construction block from the front layer, rear layer and the middle layer between the front layer and the rear layer; forming multiple such construction blocks; wherein the front layers form a tessellating pattern and the rear layers form a tessellating pattern when the construction blocks are placed in a planar arrangement; wherein at least some of the construction blocks have middle layers which provide projections which protrude from one or more sides of the construction block, wherein at least some of construction blocks have middle layers which provide recesses on one or more sides of the construction block; wherein the recesses are configured to engage with the projections such that when a projection is engaged with a recess, the projection at least substantially fills the recess it is engaged with; wherein when a projection of one construction block engages with a recess of another construction block, the two construction blocks are restricted from relative movement in the direction perpendicular to the plane of the tessellating pattern.
23. The method as claimed in claim 22, wherein forming the middle layer comprises taking a layer with a cross section of the first two-dimensional shape and either adding additional parts to the layer or removing parts of the layer.
24. A method as claimed in claim 23, wherein the adding comprises arranging multiple identical circle sectors in an arrangement, and superimposing the arrangement and the layer, and wherein the removing comprises arranging multiple identical circle sectors in a second arrangement, arranging the layer to overlie the second arrangement or vice versa, and removing the parts of the layer which overlie or are overlaid by the circle sectors.
25. The method as claimed in any of claims 22 to 23, wherein forming a construction block comprises pouring a settable liquid into a mold, wherein the mold provides the construction block with the front layer, middle layer and rear layer integrally formed together.
26. A method as claimed in claim 25, wherein the mold comprises sections which provide angled faces for the front and rear layers.
27. A method as claimed in any of claims 22 to 24, wherein forming a construction block from the front layer, rear layer and the middle layer between the front layer and the rear layer comprises attaching the layers together by attachment means to form the construction block.
28. A method as claimed in any of claims 22 to 27, further comprising forming at least two additional middle layers for each construction block, wherein one of the additional middle layers has a cross section of the first two-dimensional shape, and another of the additional layers has a cross section of the second two-dimensional 5 shape.
29. A method as claimed in any of claims 22 to 28, wherein the method comprises forming multiple projections and/or recesses on each middle layer.15 20 25 30