NL2018727B1

NL2018727B1 - Method and system for building walls

Info

Publication number: NL2018727B1
Application number: NL2018727A
Authority: NL
Inventors: Deen Dennis; Blom Johan
Original assignee: B&D Opmeer B V
Priority date: 2016-04-18
Filing date: 2017-04-18
Publication date: 2018-08-14
Also published as: EP3445924B1; NL2021427A; EP3445924A1; NL2018727A; EP3445924C0; NL2021427B1; WO2017183967A1

Abstract

A method of build i ng a wall compr i ses stacking a l ternat i ng l ayers of build i ng b l ocks and jo i n i ng b l ocks on to each other wi th the jo i n i ng b l ocks be i ng at l east part l y rece i ved i n grooves of over l y i ng and under l y i ng build i ng b l ocks such that i n each vert i cal pai r o f a build i ng b l ock and a jo i n i ng b l ock rece i ved there i n the respect i ve support surf aces engage each other and support the respect i ve h i gher b l ock on the respect i ve l ower b l ock. I n each build i ng b l ock a second groove of the grooves i s f ormed , i n part i cul ar cut , i nto the respect i ve s i de of the build i ng b l ock such that at l east one of a pos i t i on , shape and or i entat i on of the support surf ace i n the build i ng b l ock of sai d second groove i s determined by at l east one of a pos i t i on , shape and or i entat i on i n the build i ng b l ock of the support surf ace of at l east a fi rst groove of the grooves .

Description

TECHNICAL FIELD

The present disclosure relates to building walls, in particular dry walls.

BACKGROUND

Construction of walls from construction blocks using bricks and mortar and the like is generally known. Dry wall constructions are also known.

Recent developments are disclosed by, e.g., US 6,000,186, relating to a drywall construction and means therefor, AU 28415/77, relating to construction of vertical walls of buildings, FR 2,720,425, relating to a coupling arrangement for two construction elements, connecting pieces and construction elements adapted for such an arrangement, NL 1019433, relating to an assembly of stackable building stones, building stones and coupling element of the assembly, and the product FixBrick of company Earth and Eternity B.V.

Further reference may be made to FR 2575268, relating to moulded bricks for stabilisation of dikes, horticultural installations etc. and US 4,986,048, relating to a method for erecting a glass block wall, and US 5,193,320 relating to a masonry laying device.

However, there is a continuing search for improvements in building walls, e.g. with respect to material costs, manufacturing cost and user-friendliness.

SUMMARY

In particular in view of the above, inter alia, herewith a method, a system, a cutting tool, building blocks and a wall are provided according to the following.

In an aspect, a method of building a wall is provided. The method comprises

- providing building blocks and joining blocks, wherein opposite top and bottom sides of the building blocks each comprise at least one groove containing a support surface, wherein opposite top and bottom sides of the joining blocks each comprise at least one structure, in particular at least one rib, fitting at least one of the grooves of a building block and having a support surface; and

- stacking alternating layers of building blocks and joining blocks on to each other with the top and bottom sides of vertically adjacent building blocks oriented towards each other and the joining blocks being at least partly received in the grooves of overlying and underlying building blocks such that in each vertical pair of a building block and a joining block received therein the respective support surfaces engage each other and support the respective higher block on the respective lower block.

In each building block a first groove is formed, in particular cut, into one of the top and bottom sides of the building block and a second groove is formed, in particular cut, into the opposite one of the top and bottom sides. At least one of a position, shape and orientation of the support surface in the building block of said second groove is formed relative to a reference.

In the method, the first and second grooves are formed relative to the same reference and/or the reference for the second groove is provided by at least one of a position, shape and orientation in the building block of at least a portion of the first groove, in particular at least the support surface of the first groove.

When forming the first and second grooves relative to the same reference, they may be formed simultaneously relative to the same reference. When forming the first and second grooves relative to the same reference, the building block and the reference are preferably positioned and oriented with respect to each other in the same predetermined position and orientation in at least one relative direction, more preferably being in the same relative position and orientation, so that the reference relates to positions and orientations with respect to the building block in a predetermined and reliable manner.

In the method, when stacked, at least the building blocks are separate from each other and preferably, in each vertical pair the respective blocks do not support each other apart from at the support surfaces, preventing interference with the accurate positioning governed by the support surfaces. The support surfaces of a groove may be formed by the bottom of the groove.

By forming the first and second grooves to the same reference, accurate control over the position and/or orientation of the respective support surfaces is facilitated.

By forming the second groove such that at least one of a position, shape and orientation of the support surface in the building block of said second groove is determined by at least one of a position, shape and orientation in the building block of the support surface of at least a first groove of the grooves, the relative positions and/or orientations of the first and second grooves are defined to a high precision at a relatively low cost. For it has been found that dry wall buildings suffer from tolerance stacking, wherein size fluctuations of elements of different layers add up so that after several layers the wall may deviate from its intended size, in particular its height. This may be acceptable for free-standing objects, dikes and horticulture etc., but not for houses, offices etc. Moreover, there is a development towards specifying entire buildings and any components therein to ever smaller tolerances, even down to the size and pitch of masonry of walls, so that parts may be manufactured to predefined sizes in advance and construction and/or installation work on site is reduced. In the traditional way of building, skilled adjustment of mortar and/or cement layers allows for adaptation of varying brick sizes and shapes to such design requirements. However, the numbers of sufficiently skilled masons are dwindling and in any case the construction speed is determined by the process time of setting of the mortar and/or cement layers to allow addition of a further layer of bricks on a wall without deforming a previous layer underneath .

In dry wall constructions in which tolerances to size and stability are tight, currently the top and bottom sides of the building blocks are milled or polished to size. This is expensive and it provides buildings with a relatively harsh and/or sterile appearance. In the building blocks of the presently provided method, only the support surfaces of the grooves need be formed to an accuracy to prevent unacceptable tolerance stacking, enabling reduction of material consumption and/or tool wear. Further, processing time per building block may be reduced. By forming the support portions in the grooves, the shape, position and/or orientation of the support portions relative to the top/bottom sides of the building blocks may be obscured by the lateral portions of the building block defining the grooves. This enables use of blocks with large variations in their outer surface shape and/or size without affecting building tolerances, enabling benefits in one or more of material costs, production costs and appearance of the wall. The joining blocks may be made to accuracy by the same techniques as the building blocks or other techniques providing uniformity, wherein the uniformity may be masked by the building blocks. Cost benefits due to the speed and ease of the method are considered to outweigh possible elevated costs for manufacturing the building blocks and joining blocks over traditional materials like (mortar and) bricks without further processing thereof.

In an embodiment, in each building block a second groove of the grooves is formed, in particular cut, into the respective side of the building block such that at least one of a position, shape and orientation of the support surface in the building block of said second groove is determined by at least one of a position, shape and orientation in the building block of the support surface of at least a first groove of the grooves .

In an embodiment, in each building block the first groove is formed, in particular cut, into a first side of the building block, wherein at least one of the position, shape and orientation of the first groove in the building block is determined relative to a reference, in particular a reference surface, and the second groove is cut into the building block in at least one of a predetermined position, a predetermined shape and a predetermined orientation, relative to the reference, in particular providing a predetermined vertical separation from the first groove.

This facilitates determining at least one of the position, the shape and the orientation of the second groove in the block to form the building block while manipulating the building block, e.g. when rotating the block to form the second groove in the opposite side relative to the first groove. Cutting techniques, e.g. one or more of hacking, sawing, milling, drilling, grinding, polishing, etching, etc. have proven to allow reliable manufacturing for forming grooves in building material, which itself may have a rough outer shape. Thus, such post-processing enables use of otherwise more or less irregularly shaped building blocks. Milling and/or sawing can generally be performed at great speed also on site in a construction site.

In an embodiment, the second groove is cut into the building block by relative movement of the building block and a cutting tool, and wherein the position and/or motion of the cutting tool is controlled with respect to the support surface of the first groove and/or the reference, if applicable. The control can be active, e.g. as in controlled machining, or passive, e.g. wherein deviation from a predetermined setting is monitored and corrective measures are taken when required, also, the control can be done by a worker and/or it can be at least partly machine controlled e.g. as in CNC-machining.

In an embodiment, the reference is provided by one or more objects, e.g. a rib, a rail, a conveyor belt, one or more rollers, or a combination thereof, the building block is placed over the reference, the position and/or motion of the cutting tool is controlled with respect to the reference, and the building block or the cutting tool is moved with respect to the reference. In particular embodiments the building block is slid and/or rolled over the reference underneath a cutting tool that is stationary with respect to the reference. This facilitates the manufacturing by reduction of a number of moving parts, e.g. to just the part to be worked.

The cutting tool as a whole may be stationary while an operably cutting part of the cutting tool, e.g. a drill bit, a mill bit, a saw blade etc., is moving about a stationary position.

In an embodiment, opposite top and bottom sides of the building blocks comprise plural such grooves containing a support surface, and wherein opposite top and bottom sides of the joining blocks comprise plural such structures fitting the grooves of the building blocks and having support surfaces. This may increase ease of construction and it may allow increasing stability of the building block and of the wall as a whole.

In an embodiment, plural first grooves and/or second grooves may be formed in one building block simultaneously, accelerating manufacturing.

The grooves of one or both sides of the building blocks may differ in any of shape, size, position and/or orientation relative to another groove and/or to a portion of the building block. However in embodiments grooves of one or both sides of the building blocks may be one or more of extending parallel, being of identical shape, being of identical size, and having their respective support surfaces extending in a common plane in a vertical and/or horizontal direction relative to a regular position of the building block in the wall. Also, the structures of one or both sides of the joining blocks may differ and they may be one or more of extending parallel, being of identical shape, being of identical size, and having their respective support surfaces extending in a common plane in a vertical and/or horizontal direction relative to a regular position of the joining block in the wall. This may facilitate production and it may further increase stability of the building block and of the wall as a whole. In a preferred embodiment, the respective support surfaces are substantially planar in a horizontal plane in operably stacked position of the blocks.

In at least some of the building blocks the grooves may extend over an entire length of the respective top and/or bottom side, in which case they may have open ends. This facilitates positioning of the building blocks and it facilitates manufacturing by sliding the block over the reference as explained elsewhere herein.

In at least some other ones of the building blocks the grooves may extend over less than an entire length of the respective top and/or bottom side. This may facilitate longitudinal alignment of the building block to a reference and/or longitudinal locking of a building block. Further, it may improve aesthetic value of corners and/or other wall ends which may remain unaffected by the grooves in the respective top and/or bottom side. Grooves in one or more of the respective top and/or bottom sides may extend in different directions to each other, in particular perpendicular to each other. This may facilitate longitudinal alignment of the building block to a reference and it may facilitate constructing corners and/or connections of plural walls.

The grooves of one of the sides of the building blocks may be first grooves and the grooves of the other one of the sides of the building blocks may be second grooves as specified before, i.e. grooves on one side of the building block may be formed first and the grooves on the opposite side may be formed thereafter based on at least one of the position, shape and orientation of (the support surfaces of) the first grooves. This facilitates manufacturing the building blocks .

An embodiment comprises building the wall adjacent another wall and connecting the respective walls together with anchors, wherein the anchors may be attached to the joining blocks and wherein each of the respective walls may be a wall according to at least one embodiment of the method disclosed herein. Anchors may increase stability of the walls with respect to each other and/or assist in aligning the walls relative to each other. Further, accessory objects, e.g. water conduits and/or electrical cords, may be supported by the anchors. At least parts of the connected walls may be of the same type and/or construction, or they may differ. Anchors may be fixed by clamping, friction fit, screwing into a joining block and/or building block. An anchor may be used to align a wall relative to another object, e.g. another wall. Suitable anchors may be single objects or be modular, assembled from separate anchor modules. Modular anchors may comprise connector modules on opposite ends and possibly one or more spacers joining the connector modules. Each connector module is formed for fixing the connector module, and for eventually fixing an assembled anchor comprising the respective connector module, by clamping, friction fit, screwing into, and/or hooking or otherwise suitably engaging a joining block and/or building block. Modular anchors may be assembled with modules sized and/or shaped in accordance with actual requirements, e.g. sizes, shapes, thermal and/or strength properties of the construction work. The anchors may be length adjustable, e.g. the modules being connectable in different configurations and/or an anchor module being size adjustable. Here, adjustable and the like refers to non-destructive size adjustment, in particular reversible size adjustment (e.g. different from permanent techniques such as cutting a module to smaller size, etc.).

The anchors and joining blocks may comprise mated connectors, like one or more posts or recesses on/in a joining block and one or more complementary shaped eyes, hooks, protrusions etc. on an anchor.

The building blocks and the joining blocks may be of different materials, e.g. bricks or concrete and, respectively, a polymer material. This may reduce costs and/or it may help mimicking traditional brick and mortar building style. Also, different materials may facilitate attaching objects to the wall using different techniques. Various polymer materials have proven to be sufficiently strong for construction of multiple-storey buildings like houses in which the building blocks are traditional bricks, when the latter are provided with grooves in accordance with the disclosure.

In particular the building blocks may be formed by shaping a malleable material and allowing and/or forcing the shaped material to harden, e.g. by one or more processes of drying, curing and baking, and by forming the grooves of the building blocks in the hardened material. This accommodates using materials wherein the hardening may produce unpredictable deformations relative to the unhardened shape, such as tends to occur by moulding, drying and baking clay to bricks and/or by moulding and drying concrete, which are generally the optimum building materials for walls of houses and similar constructions. However other building blocks may be made by cutting, e.g. sawing or hewing, the building block from a larger object e.g. natural stone blocks cut from a rock .

In particular the joining blocks may be formed at least partly by moulding and/or extrusion processes, e.g. forming the joining blocks by extrusion of a polymer material, e.g. a polyolefin like a polyethylene (PE) and/or a polypropylene (PP), which may be of (ultra-) high molecular weight and/or be reinforced with (glass) fibres, wires, rods and/or other fortification additives. Polyolefins, in particular PE and PP varieties, are proven for use in building construction work, e.g. for housing, being heat resistant, fire-safe and readily workable with woodworking tools, and having thermal expansion characteristics similar to those of concrete and/or bricks.

Metals may also be used as construction material, in particular for joining blocks. Several metals and alloys can be suitably extruded or moulded, and may readily be formed for construction of buildings, most notably aluminium and aluminium alloys.

Another option which may be preferred is extrusion of a concrete extraction product. A suitable concrete material can be processed to a desired shape in a robust form. When the material is wetted it may attach and fix itself to surrounding materials, in particular stone-like materials like concrete and brick, with little to no shape change. However, the adherence is strong and permanent. Hosing a (partly) finished wall may therefore fortify the wall.

The joining blocks being received in the building blocks facilitates making that they are less exposed to weather and/or other external influences. Also, it facilitates making the joining blocks smaller than the building blocks, in particular in directions perpendicular to the directions of the wall. This facilitates use of a possibly more susceptible or delicate material than that of the building blocks.

In an embodiment, in the wall joining blocks are receded behind a wall surface defined by side surfaces of building blocks, forming recesses, and wherein the method further comprises filling at least part of the recesses with a filler material. This may serve for structural integration and/or fortification of the wall e.g. by covering the joining blocks, but also or alternatively for decoration and/or adaptation to a masonry style. The filler material may be a malleable material that can harden when inserted into the recess. In an embodiment, a filler material may formed one or more preformed objects, e.g. ornamental elements like coloured plates or strips and/or protective elements covering a portion of an adjacent joining block. A building block may be formed at least partially to accommodate such object, e.g. having a widened groove, and/or the filler material may be attached to a joining block.

In an aspect a system is provided for building a wall according to the present disclosure, which comprises the building blocks and the joining blocks and optionally at least one of the cutting tool, the reference and/or an anchor as disclosed. A clamp or anchor may also be provided for anchoring and/or clamping portions of the same wall together, e.g. in vertical and/or horizontal directions. This may fortify a wall. However, it is considered that fortification and/or adhesion between building blocks and joining blocks may not be required for a reliable wall.

In an embodiment, the system comprises joining plates configured to be accommodated between building blocks in at least one of the building block layers and extending from one joining block layer to an adjacent joining block layer. These joining plates may be used to close off gaps between building blocks adjacent each other in a building block layer. The joining plates may serve for structural integration and/or fortification of the wall, but also or alternatively for adaptation to a masonry style.

The building blocks may comprise grooves in lateral sides and/or end sides, relative to top and bottom sides. In particular in sides configured to face a corresponding side of adjacent building blocks within a building block layer, such grooves may in particular run in a direction from the top side to the bottom sides and more in particular over the entire side. E.g. for preventing gaps and/or increasing lateral strength of the wall, end sides and/or lateral sides of building blocks may be provided with end grooves running in a direction from the top to the bottom sides and joining plates may be provided with protruding structures fitting the end grooves. This may also be employed in a corner, where building blocks meet end side to lateral side, for beautifying and/or fortifying the corner.

Just as with the considerations regarding manufacturing the building blocks and joining blocks discussed herein in significant detail in relation to grooves and ribs and positioning surfaces in the (vertical) stacking direction, a method of building a layer is provided, in particular a layer in a wall as described herein, comprising providing building blocks and joining plates, wherein opposite end sides of the building blocks each comprise at least one groove containing a positioning surface, wherein opposite end sides of the joining plates each comprise at least one end structure, in particular at least one rib, fitting at least one of the end grooves of a building block and having a positioning surface; and

- positioning a row of building blocks and joining plates next to each other with the end sides of adjacent building blocks oriented towards each other and the joining plates being at least partly received in the end grooves of opposite adjacent building blocks such that in each adjacent pair of a building block and a joining plate received therein the respective positioning surfaces engage each other and position the respective block against each other;

wherein in each building block a first end groove is formed, in particular cut, into one of the end sides of the building block and a second end groove is formed, in particular cut, into the opposite one of the end sides, and wherein at least one of a position, shape and orientation of the positioning surface in the building block of said second end groove is formed relative to a reference, wherein the first and second end grooves are formed relative to the same reference, in particular being formed simultaneously relative to the same reference, and/or wherein the reference is provided by at least one of a position, shape and orientation in the building block of at least a portion of the first end groove, in particular at least the positioning surface of the first end groove.

This improves meeting longitudinal tolerances in a building block layer wherein the building blocks are placed in a row end side to end side with joining plates in between. All other details, elements, aspects, benefits, etc. of embodiments of methods, systems, walls etc. discussed in relation to the support surfaces and support structures of the building blocks and joining blocks, respectively, with respect to the stacking direction of layers of building blocks and joining blocks, e.g. cutting of grooves in top and bottom sides of building blocks, shapes of joining blocks, etc. may be applied and/or employed mutatis mutandis in respect of positioning surfaces and positioning structures of the building blocks and joining blocks, respectively, with respect to the length direction (row direction) in rows of building blocks and joining blocks.

One or more joining plates and joining blocks may comprise mated connectors to provide an interconnection stronger than pure stacking e.g. one or more protrusions and, respectively, recesses, such as ribs and grooves. This facilitates building a wall and may improve robustness of the wall. The mated connectors may provide an interlock in the direction of stacking the wall, providing a vertical fortification .

One or more joining plates may comprise the connectors on opposite sides to connect to joining blocks on opposite sides of a building block. Thus, a vertical interlocking of joining blocks and joining plates is achieved which improves robustness of the wall.

The connectors may be formed to provide interconnection of a joining plate to a joining block at several selectable longitudinal positions along the joining block, preferably at arbitrary positions in one or more portions. E.g. the connectors may be provided with protrusions and/or recesses, e.g. ribs and/or grooves cooperating with mated grooves and/or ribs, respectively, which ribs and/or grooves may be interrupted and/or continuous. This facilitates adaptation of the position of a joining plate during construction, e.g. in view of sizes of building blocks, of masonry design etc.

The connectors may facilitate connection by snapping and/or connection in at least one direction different to a direction of interlocking, e.g. rotary connection, facilitating connection during construction of a wall, yet enabling a strong interconnection.

Joining plates and/or joining blocks may be provided with recesses or through holes for accommodating an adhesive. A through hole facilitates connection of another object, e.g. an insulation material, and it enables in particular a continuous extension of an adhesive from one building block to an adjacent building block on opposite side of the respective joining block and/or -plate. The adhesive may comprise a cement, a mortar, a concrete, glue, etc. This may facilitate providing additional robustness of the wall; note that building blocks, e.g. bricks, may have different absorption and adhesion to an adhesive than the joining blocks and/or joining plates. A through hole, if left at least partially open from an adhesive, may further serve for ventilation and/or draining. Further, recesses and through holes, in particular large ones, reduce material and weight.

In an embodiment, in at least some of the building blocks the grooves extend over an entire length of the respective top and/or bottom side, and in at least some other ones of the building blocks the grooves extend over less than an entire length of the respective top and/or bottom side, and wherein grooves in one or more of the respective top and/or bottom sides first and/or second grooves may extend in different non-parallel directions to each other, in particular perpendicular to each other. Grooves extending over an entire length of the respective top and/or bottom side facilitate manufacturing and stacking; grooves extending along part of a building block and/or grooves in different non-parallel directions may facilitate alignment and/or fixing relative positions and/or connections with other wall portions.

An aspect comprises a cutting tool for cutting first and second grooves into building blocks for the method of any one of claims 1-8 and/or the system of any one of claims 9-12, comprising first and second operable cutters such as a drill bit, a mill bit, a saw blade etc. located on opposite sides of a path. The cutters preferably are adjustable with respect to each other in position and/or orientation, at least in one direction, and fixable in one or more predetermined positions and/or orientations. The cutting tool may comprise a sensor for detecting a position and/or movement of a first one of the cutters relative to a second one of the cutters and/or relative to a reference, in particular a rib and/or one or more rollers, preferably opposite the cutter, for engaging a support surface of a first groove of a building block in which a second groove is to be cut and/or relative to the building block to be cut; and a controller connected to the sensor configured to provide a warning signal and/or a control signal based on a detection signal from the sensor, wherein the controller may be configured to adjust the relative position and/or movement of the first cutter relative to the second cutter, to the reference and/or to the building block to be cut based on the warning signal and/or the control signal.

An aspect comprises a cutting tool, for cutting second grooves into building blocks for the method and/or the system disclosed herein. The cutting tool comprises an operable cutter such as a drill bit, a mill bit, a saw blade etc.; a reference opposite the cutter for engaging a support surface a first groove of a building block in which a second groove is to be cut, in particular a rib; a sensor for detecting a position and/or movement of the cutter relative to the reference and/or the building block to be cut; and a controller connected to the sensor configured to provide a warning signal and/or a control signal based on a detection signal from the sensor. The cutting tool may be formed from a stone saw or -mill. The sensor may comprise a non-contact sensor such as an optical sensor, e.g. a photo-cell which may be in combination with a light source, a camera, etc., which might be used while a cutter of the cutting tool is moving. A mechanical sensor, e.g. a contact measuring device may also be used, possibly in combination with a non-contact sensor.

In an embodiment, the cutting tool comprises plural cutters adjacent each other and plural references, e.g. ribs and/or rollers, adjacent each other for simultaneously cutting plural second grooves relative to the references.

Another aspect is a combination of a cutting tool and one or more joining blocks as provided herein, the joining block comprises plural ribs adjacent each other provided with support surfaces and wherein the cutting tool comprises plural cutters positioned adjacent each other corresponding to the relative positions of the ribs for cutting grooves into building blocks, such that they can be stacked together with the joining blocks in accordance with the method.

Other aspects provided herewith comprise a joining block, a building block, a joining plate, a wall, a wall assembly and a building, e.g. a house or a an office. Note that a wall as provided herein, in particular a dry wall, may be easily disassembled (de-stacking) with the building blocks and joining blocks being reusable without significant quality loss .

In an embodiment, the total area of the support surfaces in the groove or grooves in a respective top or bottom side, e.g. as defined by the lateral walls and/or end walls of the groove(s) in the respective top or bottom side, may be well below 50%, in particular in a range of between 1% and 25% and in particular between 5% and 20% of the area of the respective top or bottom side. It has been found that common building blocks like bricks and concrete blocks can readily support their rated weight at such fractions, whereas formation of the grooves may not be complex; e.g. relatively narrow and common cutters like saw blades or mill bits may be used. Also, meeting tolerances, like planarity, of smaller portions of an object and/or surface may be achieved simpler than such tolerances of large surfaces. The volume of the grooves relative to the volume of the building block may be rather small and significantly less than 20%, e.g. in a range of between 0,1% and 10%, e.g. between 0,5% and 5%. This may save cutting tool wear.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-described aspects will hereafter be more explained with further details and benefits with reference to the drawings showing a number of embodiments by way of example, wherein:

Figs. 1-2 show, from generally opposite directions, two walls 1 joined in a corner;

Figs. 3-4 are exploded views of Figs. 1-2;

Figs. 5-6 show two embodiments of building blocks;

Fig. 7 shows joining blocks and joining plates in an assembled configuration;

Figs. 8 and 9 show further embodiments of a wall;

Fig. 10 indicates method steps of an embodiment;

Figs. 11A-11D indicate a cutting tool and method steps of another embodiment;

Figs. 12A-12C show an embodiment of a wall and associated elements;

Figs. 13A-15 are cross section views of different embodiments of a wall;

Figs. 16-18 show a further embodiment of a joining block, a joining plate and a resulting associated wall segment;

Figs. 19-20 show embodiments of building blocks;

Figs. 21A-21D show another joining plate;

Fig. 22 show a wall portion and associated elements;

Figs. 23A-24B show different joining blocks;

Figs. 25A-27D show different anchor connectors;

Figs. 28-29 are cross section views of different embodiments of a wall;

Figs. 30-31 show different wall portions and elements;

Figs. 32A-33B show joining blocks and profile elements

Figs. 34A-34B show different cross section views of an embodiment of a wall.

DETAILED DESCRIPTION OF EMBODIMENTS

It is noted that the drawings are schematic, not necessarily to scale and that details that are not required for understanding the present invention may have been omitted. The terms upward, downward, below, above, and the like relate to the embodiments as oriented in the drawings, unless otherwise specified. Further, elements that are at least substantially identical or that perform an at least substantially identical function are denoted by the same numeral, where helpful individualised with alphabetic suffixes .

Figs. 1-4 show, from generally opposite directions, two walls 1 in normal view and exploded view, respectively. The walls 1 are connected in a corner, here in a substantially perpendicular orientation to each other.

For ease of reference the following is noted: the walls 1 each have a height in a vertical direction Z, a length in a respective horizontal length direction L and a width in a transverse width direction W, all mutually perpendicular to each other as indicated in each Figure.

The walls 1 are formed by stacking alternating layers B, J of building blocks 3, 4 and joining blocks 5 on to each other. The building blocks 3, 4 are shown in more detail in

Figs. 5 and 6, respectively. The joining blocks 5 are shown in more detail in Fig. 7. Optional joining plates 7 are accommodated between building blocks 3, 4, in the building block layers B and extending from one joining block layer J to an adjacent joining block layer J, as shown in more detail in Fig. 7. Optional end plates 9 are accommodated between building blocks 4, in the joining block layers J and extending from one building block layer B to an adjacent building block layer B, obscuring an end surface of an adjacent joining block 5 .

The walls 1 are provided with optional anchors, for connecting the respective wall 1 to another object, e.g. a further wall (not shown). In the shown embodiment, anchors 1115 are connected to joining blocks 5 and to joining plates 7. Anchors may be connected to the building blocks and/or end plates as well. The anchors may be at least one of barbed, roughened and provided with one or more screw threads for attachment. Threads on opposing ends may be the same or different e.g. having the same or opposite helicity respect to each other and/or having equal or different pitch.

Referring also to Figs. 5 and 6; the building blocks 3, 4 of the shown embodiments are generally quader-shaped comprising a top side 17 and a bottom side 19 opposite each other, lateral faces 21, 23 opposite each other and end faces 25, 27 opposite each other. The blocks have sizes of length Lbb, width Wbb and height Hbb and, respectively Lbb', Wbb', Hbb'. However, techniques for forming the building block may generally provide building blocks with less exact and/or smooth surfaces than those shown and other shapes may be used.

In the top and bottom sides 17, 19 grooves 29 are formed defined by opposite lateral walls 31 and a bottom 33; each groove 29 has a length Lg, a width Wg in the building block. Each groove further has a depth Dge into the building block relative to the surface of the building block 3 on a lateral outside, and a depth Dgi into the building block to the surface of the building block 3 on a lateral inside. In the building block 4 of Fig. 6, the length of the grooves Lg is less than the size of the building block 4 in the respective directions of the grooves. In a preferred embodiment the top and bottom sides of the building blocks 3, 4 are not otherwise processed than formation of the grooves 29, but in some embodiments a lateral inside portion 17i and a lateral outside portion 17e of a building block 3, 4 may be at different vertical levels.

In Fig. 5 a building block 3 is shown wherein all grooves 29 are mutually parallel and parallel to the length direction L of the building block 3.

In Fig. 6 a corner building block 4 is shown, wherein is visible that one pair of grooves 29 extends parallel each other and parallel to the length direction L of the building block 4, but extending over only part of the length of the building block 4. A further pair of grooves 29' extends parallel each other and parallel to the width direction W of the building block 4, extending over only part of the width of the building block 4. The respective grooves 29, 29' intersect each other perpendicularly and end on each other, respectively, forming a straight end corner pattern. Like building block 3, the bottom side 19 of the building block 4 is provided with the same pattern and directions of grooves (not visible) as the top side 17 shown in Fig. 6.

Similar to the difference between building blocks 3 and 4; different groove patterns may be provided e.g. for joining walls in a T-shape and/or for joining walls in an Xshape (as seen in top view).

Indications for positioning and/or orienting a building block and/or joining block with respect to its intended (relative) position and/or orientation in the wall may be provided with markings on and/or in the respective building block and/or joining block, e.g. for decorative purposes and/or for providing a wall to a predefined shape which may be non-planar. Markings may be printed and/or integrated into the shape of the respective block. In a building block grooves may be formed asymmetrically in to the top and/or bottom side of a building block, e.g. offset relative to a lateral side face 21, 23 and/or a midplane of the building block. In a joining block, a small rib and/or a groove, not interfering with the support surface(s), may be provided which may be integrated in an extrusion process (e.g. in an extrusion die).

All shown grooves 29, 29' contain support surfaces, in the shown embodiment being provided by the respective bottoms 33 of the grooves 29, 29', which here are continuous.

In other embodiments, not shown, support surfaces in a groove may be provided in only a portion of the length of a groove and/or may be separated from the bottom of a groove such as by ribs on a lateral wall and/or bottom of a groove etc.

Fig. 7 shows an embodiment of two joining blocks 5 and two joining plates 7 in an assembled configuration. The joining blocks 5 have a base 37 and ribs 39 of height Hr perpendicular to the base 37 providing a general H-shape. The base 37 has a height Hb and the total height of the joining block 5 is Hjb. The joining block 5 has a constant shape and size along its length. The top and bottom surfaces 40, respectively, of the ribs 39 form the support surfaces 40 of the joining blocks 75.

The joining blocks 5 comprise a number of connectors

41, 43 for connection with an anchor, e.g. anchors 11-15 (Figs. 1-4). In a simple embodiment as shown, the connectors 41, 43 may be or comprise holes, which may be threaded holes. In other embodiments, the connectors may comprise recessed grooves that may be curved and/or of varying width in the base and/or the ribs.

The joining plates 7 have a shape complimentary to the shapes of the building blocks 3, 4 and the joining blocks 5 as elucidated hereafter. The joining plates 7 may also have one or more connectors 45 for connection with an anchor, e.g. anchors 11-15 (Figs. 1-4).

In the shown building blocks 3, all grooves 29 extend parallel to each other wherein the bottoms 33 of the grooves 29 extend pairwise in a common plane in a vertical and horizontal direction, respectively; the grooves 29 in the top and bottom sides overlapping each other. In the shown building blocks 4 all grooves 29 and all grooves 29' also extend parallel to each other in the respective mutually perpendicular directions, wherein the bottoms 33 of all

4 grooves 29, 29' are planar and extend in a common plane in a horizontal direction per side (top side, bottom side). In vertical direction the grooves in the top and bottom sides overlap each other. In the shown embodiments, all grooves 29, 29' are formed the same by cutting, see below.

In each building block 3, 4, the relative orientation and the vertical separation Hss of the support surfaces 33 in the building block 3, 4 is determined to a high precision by determining the position and orientation of the grooves 29 relative to the position and orientation of a portion of one groove 29, in particular an initial groove 29, in the building block, rather than relying on the shape of the building block in other locations, e.g. a surface portion, and rather than forming entire exterior surfaces of the building block to a desired shape and/or size.

In the wall 1, best seen in the left-hand side of Fig. 2, alternating layers B, J of building blocks 3, 4 and joining blocks 5 are stacked on to each other with the top and bottom sides 17, 19, of vertically adjacent building blocks 3, 4, oriented towards each other. The ribs 39 of the joining blocks 5 are at least partly received in the grooves 29 of overlying and underlying building blocks 3, 4, respectively.

For such reception, the widths Wr and lateral rib separation Wsr of the ribs 39 of the joining blocks 5 should match the widths Wg and lateral gap separation Wsg of the grooves of the respective building blocks 3, 4, possibly with a friction fit,

e.g. Wr = Wg and/or Wsg = Wrg in one or more portions, to reduce play and provide retention force of the joining block into the building block. The reception interlocks the blocks 3, 4; 5 in lateral direction, which is increased by a friction fit. A friction fit may also provide longitudinal locking without requiring adhesive and/or a fastener. For a friction fit the rib 39 may be provided with one or more laterally (W25 direction) protruding structures, e.g. one or more bumps, barbs and/or ribs, which preferably is elastically deformable.

The respective blocks 3, 4; 5 may be aligned in longitudinal direction in adjacent layers but a staggered laying pattern, as shown, provides strength and stability. The joining blocks may have different length than the building blocks, in particular regular multiples of building block lengths, e.g. 2, 3, or 4 times a building block length.

In each side of the joining blocks 5, the heights Hr of the ribs 39 relative to the base 37 of the joining block 5 are made such that the heights Hr are equal to or larger than the depth Dgi of the grooves 29 of the building block 3, 4 into which the ribs 39 are to be received. In particular larger than the largest depth Dgi to be expected in case of local depth variations such as will occur in building blocks 3, 4 with varying surface shape, e.g. having a rough and/or erratic surface texture.

Thus, in each vertical pair of a building block 3, 4, and a joining block 5 received therein, be it with the building block 3, 4 underneath and the joining block 5 on top or the other way around, the respective support surfaces 33, 40, engage each other and support the respective higher block, e.g. building block 3, 4 or joining block 5, on the respective lower block joining block 5 or building block 3, 4, respectively; i.e. the top support surfaces 33 of the building block 3, 4 engage the bottom support surfaces 40 of the joining block 5 on top of it and support the latter, and the top support surfaces 40 of the joining block 5 engage the bottom support surfaces 33 of the building block 3, 4 on top of said joining block 5 and support that building block 3, 4 and so on and so forth for higher layers J, B which are supported by (the support surfaces of) the layers B, J underneath. The building blocks 3, 4 are separate from each other and in each vertical pair of blocks 3, 4; 5 the respective blocks do not support each other apart from the support surfaces 33, 40. Hence, the stacking height of the wall 1 is well defined and a stable wall 1 is provided. Note that the overall height Hjp of joining plates 7 (surfaces 47) and the height Hjpb of profiled sides of it are equal to or less than the corresponding values Hss + 2 Dgi and Hss, respectively, of the adjacent building blocks 3, 4. Also, the height of the endplate 9 is equal to or smaller than Hss.

In the present embodiment, the joining blocks 5 and joining plates 7 have a smaller width than the building blocks providing recesses in the wall 1 (see Figs. 1-4). These recesses may be filled with a filler material, e.g. a finishing cement, mortar, silicone material etc. In an embodiment, not shown, one or more joining blocks 5 and/or joining plates 7 may be provided with a decorative surface and/or structure on a lateral outside to at least partly fill such recess (not shown).

The top and/or bottom sides may be divided by grooves placed in a range of 5-20% from a lateral face of the block, possibly in a range of 10-15% e.g. dividing the top such that the groove separation Wsg is about 40-50% of the width Wbb of the building block.

Suitable sizes may be: building block: length Lbb ca 150-250 mm, e.g. 200 mm, width Wbb of one half Lbb e.g. ca 70100 mm, height Hbb of about one quarter Lbb or less e.g. ca 20-50 mm, groove width Wg 5-10 mm e.g. 8 mm, groove lateral separation Wsg about 1/3-1/2 times Wbb, e.g. 40-50 mm such as 44 mm symmetric about the block centre, nominal groove depth Dg 20-75 mm, e.g. 50 mm; groove height separation Hss 50-90% Hbb, typically ca 75-80 % Hbb, e.g. 40 mm; joining block: length 200 mm or up to several times the length of a building block, e.g. 500-1500 mm, typically about 60-80 cm, or suitable sizes for transportation, 80 cm, 120 cm, 160 cm or 240 cm (e.g. sizes of one or discrete multiples of a standard pallet size and/or lorry size), width Wjb 50-100 mm e.g. 60-70 mm, height Hjb 10-30 mm e.g. 20-22 mm, rib height Hr ca 25-45 % Hjb, e.g. 5-10 mm such as 7 mm, base height Hb ca 5-35 % Hjb, e.g. 5-10 mm such as 8 mm, rib width Wr equal to or slightly less than Wg, e.g. 4-10 mm such as 7.5 mm. The height per layer pair J, B / B, J may then be, e.g. 62 mm of which is visible 50 mm of the building blocks and 12 mm separation between adjacent building block layers B. However, other sizes may be used as desired. In particular, very long continuous lengths of joining blocks may be used; possibly up to several meters. The building blocks are free from each other and from the joining blocks apart from the ribs within the grooves with the support surfaces engaging each other. Typically, an architect or designer would select a particular building block and the joining block should be suitably sized to fit the selected building blocks. For very wide building blocks several joining blocks may be used laterally adjacent each other within one joining block layer J supporting the building blocks together.

Fig. 8 shows an embodiment with two walls 1 of building blocks 3 and joining blocks 5, which are interconnected with straight anchors 13 in connectors 43 (cf. Fig. 7) extending laterally between joining blocks 5 adjacent each other in the respective other wall. Thus, the walls fortify one another.

Fig. 9 shows another embodiment with two walls 1 of building blocks 3 and joining blocks 5, which are interconnected with U-shaped anchors 49 in connectors 41 (cf. Fig. 7); the legs of the U-shape are connected in longitudinal connectors 41 and the base of the U-shape extends laterally between joining blocks 5 adjacent each other in the respective other wall. Thus, the walls fortify one another. The plurality of connectors 41 in the end faces of the joining blocks 5 facilitates size adaptation.

Fig. 10 indicates steps of an embodiment of the method disclosed herein.

In a first step, see Fig. 10A, a future building block 51 is provided. The block 51 may have a rough and/or profiled shape and/or surface. The block 51 is placed in a desired position to provide a first side for a subsequent method step. Here the block 51 is on a support 53 of a cutting tool 55, providing a top side of the block 51.

Then, see Fig. 10, first grooves 57 are formed in the top side of the block 51 by cutting the block 51. The shown cutting tool 55 comprises two parallel cutters 56, e.g. saw blades, for simultaneous cutting of two grooves. For this, the saw blades 55 and the block 51 may be moved relative to each other. The resultant cut block 51 is shown in Fig. 10C. The grooves 57 contain support surfaces 59. For the cutting, care may be taken that the support surfaces 59 of both grooves are planar and in one plane in the block 51.

Next, cutting tool 61 comprising a reference 65, here a pair of references 65 is provided, see Fig. 10D. Here, the references may be formed as ribs and/or one or more rollers. The cutting tool 61 comprises a pair of cutters, e.g. saw blades 67. A sensor and a controller, together indicated at 69, are provided to monitor and, if need be, to adjust a relative position, e.g. a distance D, between the reference(s) 65 and a working position of the cutter(s) 67.

Next, see Fig. 10E, the support surfaces 59 of the first grooves 57 of the block 51 are positioned relative to the reference, here being brought into contact with the reference 65 by placing the block 51 inverted relative to the previous method steps onto the reference 65 with the support surfaces 59 engaging the reference at the decisive positions.

Then, see Fig, 10F, the cutting tool 61 is used to cut second grooves 73 in the second side of the block 51 wherein the cutters 67 are maintained or controlled to the operating conditions determined before (Fig. 10D). As a result, see Fig, 10G, a building block 52 is obtained in which the position and/or orientation of the grooves 57, 71, and more relevant that/those of the support surfaces 59, 73 contained in the respective grooves are accurately determined in a an easy and reliable manner.

In another embodiment, not shown, the cutting steps may be performed by different (sets of) cutters adjacent each other, possibly in one cutting tool, and operating from opposite directions for cutting the first groove(s) and second groove(s) such that inversion of the building block may be obviated. This facilitates that the reference relates to positions and orientations with respect to the building block in a manner that is predetermined and reliable, possibly even constant.

Figs. 11A-11C show another embodiment of a cutting tool 75. Fig. 11A is a side view, Figs, 11B, 11C are cross section views as indicated with XIB, XIC, respectively, in Fig. 11A. The cutting tool 75 comprises cutters 77, e.g. mill bits or saws, opposite each other at predetermined, controllable, separation D. The cutting tool 75 comprises a support 79 for supporting the blocks 51 while being formed into building blocks. Opposite the support 79 an optional press 81 is positioned with one or more resilient elements 83 to urge the blocks 51 against the support 79 at least when cut, so as to define and maintain a position and/or orientation of a block 51 relative to the support 79 in at least one direction. The support 79 may comprise one or more lateral guides, possibly in combination with a press or clamp to further control position and/or direction of the blocks relative to the support 79 and (a trajectory through) the cutters 77 (not shown). The cutting tool 75 is also provided with an optional conveyor comprising shoes 85 or other elements that engage and propel successive building blocks 51 over the support 79 past the cutters 77 in order to cut grooves into the respective building blocks 51.

The position and/or the height Hcb, Het of at least one of the cutters 77 relative to a portion of the support 79 is adjustable to adjust a relative position, e.g. a vertical distance D, between the working positions of the cutters 77 (Figs. 11A and 11B). When passing blocks 51 through the cutting tool 75 grooves 87 in a building block 51 in opposite sides are cut simultaneously to provide the desired building block 89 (Fig. 11D), wherein the grooves 87 have bottoms forming support surfaces at the predetermined distance D. In such case, both first and second grooves 87 are cut and relate to the same reference, which may be determined by a working position of one of the cutters 77, in particular the working position Hcb of the cutter 77 closest to the support 79. As an alternative (not shown), building blocks may be held symmetrically with respect to the working positions of opposite cutters, e.g. by a suitably formed symmetric clamp. One or more sensors may be provided, optionally a controller for (automated) control of relative positions and/or orientations of the cutters 77, in particular their (here: vertical) operable separation D.

A cutting tool (not shown) may comprise one or more further cutters for cutting additional grooves in the building block 51, e.g. grooves in a side face 21, 23 and/or an end face 25, 27. Here, too, plural grooves may be formed relative to a common reference.

Figs. 12A-12C show an embodiment of a wall 91, comprising a vertical anchor 93 along the wall 91. Here, the vertical anchor 93 is attached to joining plates 95, 97 formed with a lateral extension relative to the joining plates 7 discussed supra. Here, one joining plate 95 (Fig, 12B) is of a metal and an also metallic anchor 93 is fixed to the joining plate 95 by welding. Other suitable mechanical and/or chemical attachment techniques may be suitably employed, including simple insertion with a hook portion, cf. anchor 11 in Figs 1-

4. As indicated in Fig. 12C, the anchor 93 is attached to the top joining plate 97 by passing through a through hole 99 in the joining plate 97 and being provided with a nut 101 on a threaded portion of the anchor 93. Thus, tension on the anchor 93 may be adjusted, e.g. to align the wall 91. The anchor 93 may be a rod and/or a flexible tensionable element e.g. chain and/or cable.

Figs. 13A-13B show respective details of a cross section view of an embodiment of a wall 91 as part of a house, wherein the wall 91 arranged adjacent a second wall 105 with an insulation space 107 in between. The wall 91 comprises building blocks 3, joining blocks 5, a joining plate 95', an anchor 93 and an optional decorative joining plate element 103 (Fig. 13A). On an opposite side (Fig. 13B) the anchor is attached to a floor beam 109 of the house. Like in Fig. 12C, the anchor 93 passes through a through hole in the beam 109 and a nut 101 and a washer 111 are provided on a threaded portion of the anchor 93.

Figs. 14 and 15 are a cross section views of other embodiments that are similar to Fig. 13A, 13B. In Fig. 14 the vertical anchor 93 is attached not to a joining plate, but to a foundation element 113, here with an optional (possibly chemical) attachment plug 115.

In Fig. 15 the anchor 93 is attached to bottom block 117, here using a through hole 118 in the bottom block 113 and nuts 101 on a threaded portion of the anchor 93. The bottom block 117 is provided with grooves 119 containing support surfaces 121 matching the ribs 39 and support surfaces 40 of a joining block 5 on top of and partly received in the bottom block 117, just as in the building blocks 3 and joining blocks 5 above. Note that the bottom block 117, joining block 5 and building block 3 are mutually spaced from each other except at the respective support surfaces 121, 40; 40, 33, in the respective grooves 119, 29.

In Fig. 15, the anchor 93 is also attached to a foundation element 113, with a further foundation layer 119 of mortar, concrete or the like in between; when the latter is still malleable, the bottom block 117 may be aligned to the foundation element 113 or another reference, e.g. a horizontal. This facilitates alignment of the wall 91 on top.

Fig. 16 shows a further embodiment of a joining block 5' in perspective view. Fig. 17 shows an assembly of the joining block 5' of Fig. 16 (only partly shown) and a further embodiment of a joining plate 7' in side view. Fig. 18 shows a side view (in L-direction) of the assembly of Fig. 17 with a building block 3 and a further joining block 5'.

The joining block 5' is substantially similar to the embodiments described above. Visible differences from the other embodiments comprise that the base 37' is provided with a plurality of through holes 123, the number shape and arrangement of which may be selected as desired. In the shown embodiment the vertical through holes 123 occupy a larger volume than that of the remaining material of the base 37' interconnecting the ribs 39' on opposite sides of the base 37' .

Further, one or both opposite longitudinal (L direction) ends of the joining block 5' are provided with optional longitudinal connectors, preferably mated connectors on opposite ends, here in the form of a protruding end 125 to be received in a recessed end 127 of an adjacent joining block 5', shown in more detail in Fig. 17. The protruding and recessed ends 125, 127, are formed by appropriately shaped portions of the base 37' and ribs 39' of the joining block 5'. Such connection provides lateral (W-direction) and/or vertical (Z-direction) fortification between adjacent joining blocks 5'. The connection also prevents (drafts through) gaps between adjacent joining blocks 5'. Further, an optical continuity in a series of joining blocks 5' may be provided. The longitudinal mated connectors of adjacent joining blocks may comprise interlocking features such as jigsaw-bulbs and recesses or entangling barbs.

Further, the ribs 139 of the joining block 5' are provided with optional connectors 129 (here: ribs), see below.

Best seen in Figs. 17 and 18 is that the joining plate 7' is provided with an optional large trough hole 131, rendering the joining plate 7' effectively into substantially a hollow frame having an outer shape complimentary to the shapes of the building blocks 3, 4 and the joining blocks 5', just as the substantially solid joining plates 5 discussed above, but saving material and weight and facilitating adaptation to shape and possible deformation of building blocks. The hole 131 may be filled with another material, e.g. a deformable material, preferably elastic, to accommodate shape and/size differences of adjacent building blocks 3, such as preventing gaps due to coarse building block end faces 25.

Also or alternatively, and as shown in Figs. 19-22, for preventing gaps and/or increasing lateral strength of the wall, one or both end faces 25, 27 of building blocks 3 may be provided with one or more end grooves 29 as shown in Figs. 19A and 19B, respectively, and joining plates 7 may be provided with one or more protruding structures (here ribs) 132 fitting (the end grooves 29) of the building blocks 3, providing cooperating positioning structures.

In embodiments such as shown in Figs. 17-18, the joining plate 7' is provided with optional connectors 133, mated to the connectors 129 of the joining block 5'. Best seen in Fig. 18, the connectors 129 and 133 of this embodiment form an interengaging set 137 of ribs and grooves. Such connection may be made by insertion of (the connectors 133 of) the joining plate 7' between the ribs 139 of the joining block 5' and rotating the joining block about a vertical axis (Zdirection) so that the connector set interlock and the joining plate 7' becomes oriented perpendicular to the joining block 5'. However, assisted by a tapering shape of a protrusion 135 of the joining plate 7' and a resiliency of the connector 133, (the connectors 133 of) the joining plate 7' may be inserted vertically (Z-direction) into (the space between the ribs 129 of) the joining block 5' and snapped into place effecting the desired interlock. A subsequent joining block 5' of a subsequent joining block layer J (not shown) may be interlocked in the same way by snap connection between the respective connectors 129, 133 on the opposite side of the joining plate 7'. Thus, the adjacent joining blocks are connected together.

It is noted that vertical anchors may be used also for providing vertical interconnection between adjacent joining block layers J and/or adjacent building block layers B. The connection strength of the connection may be determined by a suitable design of the joining plate. E.g. a rigidity / flexibility of (portions of) lateral plate portions 140, upper and lower plate portions 141 and the connectors 133 may be provided by adding and/or displacing upper and/or lower plate portions 141 as indicated with a dashed line in Fig. 18.

As best seen from Figs. 16-17, the connectors 129, 133 of the joining blocks 5' and joining plates 7' extend substantially uninterrupted along their respective lengths, so that the joining plates 7' may be positioned and connected at any desired longitudinal position on the joining block 5'.

Figs. 23A-24B show yet other embodiments of joining blocks 205, 205', wherein ribs 239A are formed castellated, providing a series of posts P interrupted by gaps G, so that a series of support surfaces 240A is formed. In Figs. 23A-23B, ribs 239 are full providing a full support surface 240, in Figs. 24A-24B the ribs 239B are provided with thin gaps G' extending only over part of the width of the rib 239B (W direction) leaving wall portions WP of the joining block 205' towards the lateral outside (W direction) of the gap G', resulting a support surface 240B of varying width and providing a full front face 250. The depth of the gaps G (Z direction) may be to the base 237 as shown; the gaps G' may have lesser depth which may correspond to the depth of grooves 29 in the associated building blocks so that possible visibility of the gaps G' in the front face 250 may be obscured.

		In	the base 237	of	the joining blocks	205,	205' cut
outs	223	are	formed (cf.	Figs	. 16, 17) and gaps	251.	The cut-
outs	223	and	gaps 251, G,	G'	reduce material use	: and	weight

and they facilitate manufacturing by insert moulding, in particular facilitating forming protrusions 229 on the ribs 239A, 239B. The optional protrusions 229 form connectors to mated connectors on joining plates, just as connectors 129 of Figs. 16-18. The gaps G of (castellated) joining blocks 205, 205' also facilitate ventilation of the wall. Further, the castellations facilitate connecting objects to the joining blocks 205, 205' in different positions.

In Figs. 205, 205'the gaps G, G' and thus the posts P of opposite (top/bottom) sides of the joining blocks 205, 205' are mutually staggered, but they may be in line (vertical, Z direction). In particular in a staggered castellation the gaps G, G' may be narrower than their relative separation in the length direction of the rib 239 (L direction) so that in continuous and uninterrupted structures in the direction of supporting force (Z direction) may be provided, e.g.: in Figs. 205, 205' posts P on opposite sides of the joining blocks 205, 205' at least partly overlap (in L and W directions) and provide uninterrupted rib material from the one supporting surface 240 to the opposite supporting surface 240.

Figs. 25A-25B, 26A-26C 27A-27D show different connector modules 275, 276, 277 for modular anchors in different orientations (see reference axes W, L, Z). The connectors 275, 276, 277 and at least a portion of (the castellations of) the joining blocks 205, 205' are mated, such that the connectors 275, 276, 277 fit associated portions of the castellations on one side and provide a connection portion on another side to which another anchor module may be attached.

In Figs. 25A-25B the connector 275 is generally Tshaped on one end 275A for fitting in a gap G and engaging two adjacent posts P; on the other end 275B the shown connector 275 has an angled and slotted portion for receiving (e.g. hooking) another anchor module.

In Figs. 26A-26C the connector 276 has a through hole in one end 276A and is formed for fitting around a post P and in two adjacent gaps G; the other end 276B of the shown connector 276 has an angled and slotted portion for receiving (e.g. hooking) another anchor module.

The connectors 275 and 276 are particularly suited for (use in) anchors extending in the plane of the first portions 275A, 276A of the respective anchors 275, 276, i.e. for accommodating tensile or compressive forces perpendicular to the posts P; see Figs. 28 (compare with Fig. 14).

In Figs. 27A-27C the connector 277 has three holes in one end 277A for fitting around a three adjacent posts P and in the four gaps G associated therewith; the other end 277B of the shown connector 277 has a through hole for receiving (e.g. hooking, bolting) another anchor module. Here, the connector is relatively wide (portion 277C), the width of which may correspond to the width of the base 237 of the joining block 205, 205' so that forces may be distributed. Such connector is particularly suited for (use in) an anchor extending perpendicular to the plane of the connector 277, i.e. parallel to the wall; see Fig. 29 (compare with Figs. 12A-15). Note that compared to Figs. 12-15 (use of) the connector 277 may allow replacing joining plates 97 with lighter-weight and/or hollow joining plates cf. Figs. 17-18, 22 etc. that may be able to support anchor forces.

Various elements of the Figures 19-26C may be recognized in Figs. 30-31 as indicated by the respective reference signs. Further, modular anchors 279 and 281 are shown, comprising anchor connectors 275, 276 (Figs. 25A-26C) and elongate anchor modules 283, 285 which may be screwed (283), hammered (285) and/or otherwise fixed to an object adjacent the wall 1 being constructed. The hook-shape and slot of the anchor connectors 275, 276 facilitates connection and position adjustment of the respective anchor modules (275, 276; 283, 285) to each other, e.g. by screwing and/or hooking in in a desired position, and the connectors may be used in various orientations (Figs. 28, 30-31). Such modular anchors 279, 281 also facilitate making screwed connection of one anchor module 283 to a wall or other object on one end, without rotation of the connector 275.

The corner building blocks 4 of Fig. 31 differ from corner building block 4 of Figs. 1-4, 6: in Fig. 6 the grooves

29, 29' each end in a straight end corner pattern. Such shape may be formed by milling or hacking the grooves into the building block 4. However, when using a rotary cutter, the cutting edges will have a circular circumference that becomes noticeable at a blind end of the cut. In particular, sawing grooves into the building block may be more cost- and timeeffective than milling, in particular using a circular saw or similar rotary cutter wherein the axis of rotation of the cutter and hence the circular circumference portion may be parallel to the top/bottom face of the building block. In such case, when a blind groove segment is to be made (i.e. a groove extending over only part of the width or length of the building block) using a circular saw, at the blind groove end (where the groove stops in the building block) the radius of curvature of the circular saw may become noticeable as an accordingly reducing groove depth. This is indicated in Fig. 31 at 29E. To accommodate a deviation in a planarity of the support surface joining blocks and/or endplates cooperating with building blocks having one or more groove ends may have accordingly shaped ribs or sides, e.g. being formed complementary to a radius of curvature in it. In particular, Fig. 31 shows corner joining blocks 290 having ribs 291 (or other structures) fitting a corresponding groove 29, in particular a blind groove end 29E, of an associated building block 4 and having a support surface, wherein a portion of the ribs 291 or structures is shaped in accordance with the associated grooves and/or in accordance with the shape and/or cutting pattern of the cutter used for cutting the groove ends 29E into the building block. In particular, the corner joining blocks 290 have a corner portion 293 of reduced height, the reduction being in accordance with the circumferential shape of a cut of a rotary cutter, e.g. circular saw, with which the groove ends 29E the corner blocks 4 are cut.

Further, Fig. 31 shows profiled cover elements 295,

297 that may be used in conjunction with other elements of the presently disclosed system. In particular, the elements 295, 297 may be attached to the joining blocks and/or, respectively, the joining plates, e.g. for at least partially masking and/or protecting the joining blocks and/or, respectively, the joining plates. The cover elements may have further functionality, e.g. as a light-emitting element (powered and/or luminescent). For this, the respective cover elements295, 297, joining blocks and joining plates may have corresponding connectors, e.g. a clamping arrangement as shown for two embodiments in Figs. 32A-33B. Figs. 32A and 32B show a joining plate 7 (cf. Figs. 21A-22) and a generally U-shaped cover element 297A in disconnected state (Fig. 32A) and in connected state (Fig. 32B), respectively. Figs. 33A and 33B show a joining plate 7' (cf. Figs. 17-18) and a generally nshaped cover element 297B in disconnected state (Fig. 33A) and in connected state (Fig. 33B), respectively. The cover element 297B comprises protruding structures (here ribs) 298 fitting (the end grooves 29) of the building blocks 3, providing cooperating positioning structures (like ribs 132 of the joining blocks 7). Other attachment provisions, like snapping latches etc. may be used as well. The cover elements may be accommodated between adjacent building blocks and/or in the respective grooves thereof; see Fig. 34A-34B, wherein fig, 34A is a vertical cross section through a wall and 34 B is a partial horizontal cross section as indicated in Fig. 34A. It is noted that portions of the covers may be sized in accordance with sizes of the joining blocks and/or joining plates, which are well known prior to construction a wall. Further, not shown, a combination of joining plate 7 and cover element 297B may be used wherein on one lateral side of the joining plate 1 protruding structures may be provided and on the other side of the joining plate 7 cover elements 297B providing positioning structures 298, matching the positioning structures 132 of the joining plate 7. Thus, cooperating positioning structures on opposite lateral sides (W direction) of the assembly of joining block 7 and the cover element 297B are provided. This may improve positioning and/or alignment of building blocks on opposite longitudinal sides (L direction) of the assembly.

Further, in some cases cover elements may cover one or both support surfaces of joining blocks or one or both positioning surfaces of joining plates, as the case may be, with a cover element portion. In such cases the engagement of the support surfaces and/or, respectively, the positioning surfaces may be indirect with the respective cover element portion being in between and transferring any support force between the adjacent and cooperating building block and joining block and/or any positioning force between the adjacent and cooperating building block and joining plate. A cover element may be manufactured thin and to high tolerances e.g. as an aluminium or polymer profile, possibly an extrusion profile, and retain any tolerances in a stacked wall or along a row, respectively.

Also or alternatively, cover elements may be provided with connectors, e.g. holes and/or hooks, for engaging castellations in joining blocks, similar to the anchor connector modules discussed above.

The disclosure is not restricted to the above described embodiments which can be varied in a number of ways within the scope of the claims. For instance a different number of grooves and/or ribs may be provided. Building and/or joining blocks may have different sizes, aspect ratios etc.

The grooves may have different sizes, also per side. Different constructions may be built, but the method and system disclosed herein is considered particularly useful for building 2- to 3-storey houses of bricks as building blocks with concrete extraction or polymer joining blocks.

It is noted that walls as disclosed herein may be more flexible relative to rigid brick-and-mortar or concrete walls. The flexibility may depend on fixation of building blocks and joining blocks together. A flexible wall may be able to absorb tremors, e.g. earth quakes, better than rigid walls which crack.

A building block and/or joining block may have a draining channel, which may exit on an outside of the wall. Possibly, a bottom of a groove and/or a rib of a joining block may have a (further) groove for draining and/or for collecting possible debris scraped off a building block and/or a joining block when the joining block is inserted into the groove of the building block. This may also be used to identification of a top and/or bottom side of a building block and/or joining block .

Elements and aspects discussed for or in relation with a particular embodiment may be suitably combined with elements and aspects of other embodiments, unless explicitly stated otherwise.

Claims

CONCLUSIONS

A method for building a wall comprising

- providing building blocks and connecting blocks, wherein opposite top and bottom sides of the building blocks are each provided with at least one groove containing a bearing surface, wherein opposite top and bottom sides of the connecting blocks are each provided with at least one structure, in particular at least one rib, that fits at least one of the grooves of a building block and has a bearing surface; and

- stacking alternating layers of building blocks and connecting blocks on top of each other, the top and bottom sides of vertically adjacent building blocks facing each other and the connecting blocks being at least partially accommodated in the grooves of above and below building blocks vertical pair of a building block and a connecting block included therein, the respective bearing surfaces are in communication with each other and bear the respective higher block on the respective lower block;

wherein in each building block a first groove is formed, in particular cut, in one of the top and bottom sides of the building block and a second groove is formed, in particular cut, in one of the opposite top and bottom sides, and wherein at least one of a position, shape and orientation of the bearing surface in the building block of the second groove is formed with respect to a reference, the first and second groove being formed with respect to the same reference, in particular simultaneously with respect to the same reference, and / or wherein the reference is provided by at least one of a position, shape and orientation in the building block of at least a portion of the first groove, in particular at least the bearing surface of the first groove.

Method according to claim 1, wherein in each building block the first groove is formed, in particular cut, in a first side of the building block, wherein at least one of the position, shape and orientation of the first groove in the building block is determined with respect to a reference and the second groove is cut into the building block in at least one of a predetermined position, a predetermined shape and a predetermined orientation relative to the reference.

Method according to one of the preceding claims, wherein the second groove is cut in the building block by a relative movement of the building block and a cutting tool, and wherein the position and / or movement of the cutting tool is controlled relative to the bearing surface of the building block. first groove and / or the reference, if applicable.

Method according to claim 2 or 3, wherein the reference is provided by one or more objects, for example a rib, a rail, a conveyor belt, one or more rollers or combinations thereof, the building block is placed over the reference, the position and / or or movement of the cutting tool is controlled relative to the reference, and the building block or cutting tool is moved relative to the reference, wherein in particular the building block is slid over the reference and / or rolled under a cutting tool that is stationary with respect to of the reference.

A method according to any one of the preceding claims, wherein opposite upper and lower sides of the building blocks comprise a plurality of such grooves which comprise a bearing surface, and wherein opposite upper and lower sides of the building blocks comprise a plurality of such structures which the grooves of the building blocks fit and have support;

and wherein the grooves of one or both sides of the building blocks preferably have one or more of the following properties: they extend parallel to each other, they have an identical shape, they have an identical size, and their respective bearing surfaces extend a common plane in a vertical and / or horizontal direction relative to a normal position of the building block in the wall, and wherein preferably the structure of one or both sides of the building blocks has one or more of the following properties: they extend extend parallel to each other, they have an identical shape, they have an identical dimension, and their respective bearing surfaces extend in a common plane in a vertical and / or horizontal direction relative to a normal position of the connecting block in the wall;

and wherein the grooves of one of the sides of the building blocks are first grooves and the grooves of the other sides of the building blocks can be second grooves as specified in any one of the preceding claims.

Method according to one of the preceding claims, comprising building the wall next to another wall and joining the respective walls with anchors, wherein the anchors can be fixed to the connecting blocks and wherein each of the respective walls is a wall can be according to the method according to any of the preceding claims.

Method according to one of the preceding claims, wherein the building blocks and the connecting blocks are of different materials, for example bricks and a polymer and / or concrete extraction materials, wherein in particular the building blocks can be formed by forming a deformable material and to allow and / or force the molded material to harden wherein the grooves of the building blocks are formed in the cured material, and / or the connecting blocks can be formed at least in part by an extrusion process and / or a molding process by means of a mold.

A method according to any one of the preceding claims, wherein building blocks are recessed into the wall behind a wall surface defined by side surfaces of building blocks, forming recesses, and wherein the method further filling at least a part of the recesses with a filling material includes.

A system for building a wall according to any one of the preceding claims, comprising the building blocks and the connecting blocks.

System according to claim 9, comprising the cutting tool and the reference according to claim 2 or claim 2 and one of the claims dependent on claim 2, and possibly comprising one or more anchors for the method according to claim 6 or claim 6 and one of the claim 6 dependent claims.

The system of any one of claims 9-10, comprising connecting plates to be arranged between building blocks in at least one of the building block layers and extending from one building block layer to an adjacent connecting block layer.

12. System as claimed in any of the claims 9-11, wherein in at least some building blocks one or more grooves extend over a full length of the respective top / or bottom side, and in at least some other building blocks one or more grooves extend over less then extend a full length of the respective top and / or bottom, and wherein in one or more of the respective top and / or bottom, first and / or second grooves can extend together in different non-parallel directions, in the particularly perpendicular to each other.

A cutting tool for cutting first and second grooves in building blocks for the method according to one of claims 1-8 and / or the system according to one of claims 9-12, comprising first and second operative cutting members such as a drill, a cutter , a saw blade, etc. located on opposite sides of a web;

a sensor for detecting a position and / or movement of a first of the cutting members relative to a second of the cutting members and / or relative to a reference, in particular a rib and / or one or more rollers, opposite the cutting means for communicating with a bearing surface of a first groove of a building block in which a second groove is to be cut and / or with respect to the building block to be cut; and a control member connected to the sensor and adapted to provide a warning signal and / or a control signal based on a detection signal from the sensor, the control member being adapted to detect the relative position and / or movement of the first cutter with respect to the second cutter to be adapted to the reference and / or to the building block to be cut on the basis of the warning signal and / or the control signal.

14. Cutting tool for cutting second grooves in the building blocks for the method according to one of claims 1-8 and / or the system according to one of claims 9-12, comprising an effective cutter such as a drill, a cutter, a saw blade, etc. ;

a reference, in particular a rib and / or one or more rollers, opposite the cutter for communicating with a bearing surface of a first groove of a building block in which a second groove is to be cut;

wherein the tool is adapted to cut the second groove by using the cutter while the bearing surface of the first groove is connected to control at least one of the shape, position and orientation of the second groove in the building block.

Cutting tool as claimed in claim 14, comprising a sensor for detecting a position and / or movement of at least one cutting member of the cutting tool relative to the reference and / or the building block to be cut; and a control member connected to the sensor and adapted to provide a warning signal and / or a control signal based on a detection signal from the sensor, the control member being adapted to detect the relative position and / or movement of the first cutter to be adjusted relative to the reference and / or the building block to be cut based on the warning signal and / or the control signal.

16. Cutting tool as claimed in any of the claims 13.5, comprising a plurality of cutting members that are adjacent to each other and a plurality of references, for example ribs and / or rollers, that are adjacent to each other for simultaneously cutting a plurality of second grooves .

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