WO2005108703A1

WO2005108703A1 - Construction module of tiles

Info

Publication number: WO2005108703A1
Application number: PCT/IB2005/051563
Authority: WO
Inventors: Gösta BROWNUM
Original assignee: Construnit Holding Aps
Priority date: 2004-05-12
Filing date: 2005-05-12
Publication date: 2005-11-17
Also published as: EP1751366A1

Abstract

Construction module of an appearance equal to a number of standard construction elements arranged in one or several generally horizontal rows with at least one outer surface having a desired pattern provided by differences in level, wherein said module is made in a single-step molding process from one molding paste substantially comprised of lightweight natural raw materials and having a wall thickness similar to a standard construction element. The invention anticipates the prejudice of huge brickwork not being realistically handled by the average construction worker due to heavy weight.

Description

CONSTRUCTION MODULE OF TILES

TECHNICAL FIELD

The invention relates to a construction module having dimensions equal to several standard construction elements e.g. wall bricks or roofing tiles being arranged in one or several generally horizontal rows with at least one outer surface having a desired pattern provided by differences in level.

BACKGROUND ART

Over time many efforts have been made in order to create solutions for workmen and do-it-yourself people, said solutions being economical regarding choice of material and working hours and requiring less professional skill.

Already in 1913, a British architect, Herbert Palmer developed and acquired patent rights for his "Improvements in sheets, slabs, strips, tiles, and the like for covering and constructing walls, roofs, buildings and structures" described in GB 8241. The object of this invention is to "resemble the courses, bonds, joints" etc. and the inventor wanted to "erect and sheath buildings and structures with as large sheets as possible".

US 5,570,551 "Modular Masonry Kit" describes modules manufactured from wood having contoured side surfaces providing the impression of being a module comprised by a layer of building bricks with intervening joints of mortar, a so-called course of stretchers. By arranging modules on top of each other shifted half a brick sideways, the appearance of a normal running bond was obtained.

A similar bond is described in US 6,349,522 "Brick block", wherein a complete 3- course chimney module with brick-look is molded in concrete in a multi-part mold..

The idea of manufacturing modules having a look like a section of brickwork is also known from US 4,275,540 "Plastic free standing brick wall section", wherein an artificial brick wall is built by the use of a box-like module consisting of plastic material and having a look like an even number of brick courses in running bond. The brickwork is meant to be used for a low, decorative wall, with no intention of providing a normal brick wall with required strength and insulation.

The prior art solutions are generally invented to save working hours and to reduce the demand for professional skills and to make cheaper products while in return accepting an artificial product in the form of a brickwork replica.

DISCLOSURE OF THE INVENTION

One object of the present invention is to provide a construction module, wherein the material substantially consists of lightweight natural raw materials, such that the final building structure looks like a structure built by means of traditional methods and materials. Furthermore, the construction modules are aimed at making it easy even for unskilled workers to achieve a high building quality.

Another object of the invention is to provide brickwork having good insulating properties

Yet another object is to join said modules in such manner that they are securely interconnected.

The objects mentioned above are fully or in part satisfied according to the invention by a construction module of the kind described above, being made of one molding paste of raw materials, and having a wall thickness similar to a standard construction element. Modules being pre-fabricated with an appearance equal to a number of juxtaposed standard construction elements provide for less bricklaying work and a definite uniform appearance of the finished brickwork and it mitigates settling damages over time, which again secures the desired quality of the finished brickwork.

According to the invention, said raw materials include moler, pumice, cement etc.

Modules can be laid up by simply using dry bricklaying-technique or placing insulation material between contacting surfaces, or an adhesive can be applied to such surfaces, which also ensures a good tensile strength useful to withstand larger wind loads Moreover, the use of wall ties could in many situations be omitted because an adequate stability of the wall is achieved due to coupling parts being provided on at least one side surface of a module, said coupling parts being adapted to fit together with complementary coupling parts on adjacent modules, such that the patterns of corresponding outer front surfaces fit together.

In a particularly favorable embodiment of the invention, said coupling parts are provided in the form of tongues and notches along part of or the full length of a side surface, wherein a tongue of one module fits into a notch of a juxtaposed module. These coupling parts can be formed on the lateral as well as the horizontal surfaces.

In construction modules having all dimensions equal to a standard brick wall comprising an outer surface or frontage, an inner surface and an intermediary core, which in a further embodiment contains one or several substantially vertical cavities adapted to receive cavity wall insulation, pipes or wiring, no wall ties would be needed.

Preferably, the pattern on the outer surface having differences in level appears as a traditional brickwork bond with bricks in optional types of courses and encased by raked joints, and furthermore the connection lines between modules follow the "mortar" joints.

Usually, brickwork is built with an outer flat, vertical surface, but in another advantageous embodiment of the invention, the module has a curved outer surface as seen in a horizontal cross section in its mounted position.

Modules according to the invention may also be a single leaf, which has to be tied to a substructure by means of fastening means inserted through holes provided in the joints thereof.

The construction module according to the invention may also have a front pattern providing an appearance like a tiled roof, wherein the differences in level give the impression of overlapping roof tiles. Coupling parts of this kind of module could be provided as protruding fins to be covered by a juxtaposed module.

Further, the invention relates to a method of producing brickwork consisting of a number of modules as described above, wherein initially a base is provided on which a first module is fixedly placed; next more modules of similar type are added laterally thereof or on top, thereby interconnecting the modules; and finally connection lines of modules are hidden by treating the respective joints with paint or mortar.

In an advantageous method according to the invention, fixation of a module is provided by interconnecting coupling parts e.g. complementary tongues and notches on each module and the base, respectively, together with applying to the contacting surfaces a fully or partly covering layer of adhesive and/or by using ordinary fastening means, e.g. screws, bolts or like.

The invention also relates to a method of laying up a roof covering comprising a number of roof tile modules, wherein a module is attached to and spanning the substrate or rafters of a roof; next more modules are placed in positions overlapping coupling means of previously laid modules; and all modules are being fixedly attached to the substrate by traditional connection means

The invention has overcome the typical prejudice of large construction modules being far too heavy to handle. Standard brick material shows a density of 1200-1800 kg/m³ whereby a module of a size equal to several normal bricks or tiles easily becomes too heavy to handle. According to the invention, the material being used to produce such module contains a great deal of pumice having a density of typically 600-800 kg/m³.

According to the invention it is possible to provide also special types of masonry modules, comprising such details as brick-on-edge courses, openings for windows, doors etc. having lateral side portions matching the bond.

In a special embodiment of a module providing for corner jointings, provisions have been made to configure the adjacent modules to become interlaced, thereby providing a genuine corner. A man skilled in the art could easily suggest other configurations of the complementary surfaces.

BRIEF DESCRIPTION OF THE DRAWINGS

Now, preferred embodiments of the invention will be discussed with reference to the drawings, which show:

Fig.1 a perspective view of a construction module according to the invention, Fig 2 an elevation of a construction module in a second embodiment of the invention,

Fig.2A a sectional side view A-A in the module shown in Fig.2,

Fig.2B a sectional side view B-B in the module shown in Fig.2,

Fig.2C a sectional side view C-C in the module shown in Fig 2,

Fig 3 an elevation of a quarter-circular arch,

Fig 4 a perspective view of a wall corner,

Fig.5 a roof tile module with coupling parts on two sides.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In Fig. 1, a simple embodiment of the invention is shown in the form of a construction module 10 to provide a single-brick wall in a surface pattern comprising three courses 11 in running bond, wherein differences 12 in level of the surface appear as traditional mortar joints. The sides of the module are adapted for interconnection with another module in a straight toothing.

Fig 2 shows a more elaborate embodiment for a four-course construction module 20 for a wall having on the edges thereof coupling parts 13, 14, 15 provided for use as an especially stable interconnection of adjacent construction modules. Further details to create a better understanding of the physical configuration of a construction module 20 are to be found in the three detailed drawings of figs. 2A, 2B, 2C as viewed from the ends of the module indicated by arrows A, B, C.

According to the embodiment shown coupling parts 13, 14 comprise a tongue 13 and a notch 14 meshing vertically into a corresponding notch and tongue arrangement, while the tongue 13 due to its protrusion from two perpendicularly arranged edges fits also into a notch 15 in the one side of a module.

During interconnection of construction modules 20 it could be decided to use dry laying technique, i.e. the modules are piled on top of each other and secured by means of tongues and notch arrangements not requiring the use of mortar or various types of adhesives. In an alternative bricklaying technique, sealing strips or beads are applied to the adjacent surfaces, eliminating penetration of moisture and wind. In standard brickwork, the mortar does not provide any tensile strength to the joint; however, the adhesives contribute positively to the creation of brickwork having a good tensile strength, where required

For interconnecting and securing modules to a substructure behind the brickwork fastening means like e.g. screws, bolts, nails or glue may advantageously be used.

Having interconnected the modules as described above, the connection lines and the fastening means would be hidden by painting the joints or using a mortar paste therein.

The invention also suggests specially designed modules for connecting corners, finishing a wall to one side or at openings for doors or windows, and other construction details, e.g. walls showing a curved shape protruding from the usual vertical plane of a wall. Fig. 3 shows a quarter-circular arch or half a semi-circular arch.

Fig 4 is a schematic view of two modules adapted for interconnection under an angle of 90 degrees, with sawn-off portions (shaded) of two standard modules for them to be moved or mortised into each other. The adjusted shape could also be provided directly by molding such configuration-

It should be noted that the coupling parts do not have to be positioned centrally on the side edges, they could be offset inwardly or outwardly of the central plane of the module. The brickwork shown in fig. 4 is supposed to become a wall, having brick pattern on only the one outer surface, but a bond pattern could equally well be established on both outer surfaces of the module, e.g. in case of a freestanding wall. Finally, the module could be so deep or thick that there is space enough to have at least one substantially vertical cavity, which may or may not contain insulating material.

The construction module can also take the form of a roof surface with distinguishable individual roof tiles, e.g in a 3x3 tile modus 30 shown in fig. 5. The modules can be manufactured by filling a mold with the molding paste as described above. The coupling parts 33-36 have the form of protruding fins, which is easily understood from studying the detailed views A-A and B-B in fig. 5. Sectional view A-A shows a roof tile module, where according to the preferred embodiment of the invention, virtual layers 31 and 32 constitute one homogenous layer. Sometimes the upper virtual layer 31 will extend beyond (not shown) the lower virtual layer 32 of the same module at the lowermost rim to pretend being tiles of ordinary thickness.

Laying up such roof modules is done by laying a module 30 in a position wherein it is in usual manner supported by rafters and/or battens. However, the modules could also avoid the battens by being self-supporting and having a large span width. Ledges could be provided on the rear side of the modules for attachment of the same, so it does not slide down. Next, modules are positioned in overlapping connection with the module already laid, by means of fastenings means, e.g. nails, screws, steel wire or nylon wire etc. Moreover and again, the roof modules can have the connection lines hidden by painting or sealing the lines by means of sealing or adhesive means

Claims

1. Construction module of an appearance equal to a number of standard construction elements e.g. bricks or tiles arranged in one or several generally horizontal rows with at least one outer surface having a desired pattern provided by differences in level, characterised by said module being made in a single- step molding process from one molding paste substantially comprised of lightweight natural raw materials and having a wall thickness similar to a standard construction element.

2. Module according to claim 1, characterised in comprising at least pumice, cement and water.

3. Module according to any of claims 1-2, characterised by coupling parts being provided on at least one side surface, said coupling parts being adapted to fit together with complementary coupling parts on adjacent modules, such that the patterns of corresponding outer surfaces match each other.

4. Module according to claim 3, wherein said coupling parts are provided in the form of tongues and notches along part of or the full length of a side edge, wherein a tongue of one module fits into a notch of a juxtaposed module.

5. Module according to any of the previous claims, characterised in that the pattern on an outer surface thereof showing differences in level has an appearance like a traditional brickwork bond comprising bricks in optional types of courses and encased by raked joints.

6. Module according to claim 5, c h a r a ct e ri s e d in that the lines of connection between such modules follow the "mortar" joints.

7. Module according to any one of the previous claims, characterised in that the outer surface is curved as seen in a horizontal cross section in a mounted position.

8. Module according to any one of the previous claims, characterised in that through-going holes are provided in joints for attaching the module to a support structure.

9. Module according to any one of the previous claims, characterised in that at least one substantially vertical cavity is provided in said module to contain e g insulation material, pipes or wiring.

10. Module according to any one of the previous claims, characterised in that openings for windows and doors are provided therein

11. Module according to any one of the claims 1-3, characterised in that the pattern on the outer surface thereof has an appearance as a section of roof tiles overlapping each other, and self-supporting thickness and strength.

12. Module according to claim 11, characterised in that the coupling parts are protruding fins to be covered by a juxtaposed module

13. Method of producing brickwork consisting of a number of modules according to any one of the claims 1-11, characterised in that initially a base is provided on which a first module is fixedly positioned; next more modules of similar type are added laterally thereof or on top, thereby interconnecting the modules; and finally connection of modules is hidden by treating the respective connection lines with paint or mortar.

14 Method according to claim 13, characterised in that fixation of modules to the substrate and to each other is provided by applying to the contacting surfaces a completely or partly covering layer of adhesive or by using ordinary connection means, e.g. screws, bolts or the like.

15. Method of laying up a roof surface comprising a number of roof tile modules according to any one of the claims 13-14, characterised in that a module is being attached to and spanning the substrate or rafters of a roof; next further modules are positioned overlapping coupling means of previously laid modules; and 1ϋ

all modules are being fixedly attached to the substrate by ordinary connection means, e.g. screws, bolts or like.

16. Brickwork composed of construction modules according to any one of the claims 1-10 and being laid up by the method according to claims 13-14.

17. Roof covering composed of construction modules according to claims 1-3 and 11-12 and being laid up by the method according to claim 15