WO2008059544A1

WO2008059544A1 - Improved interlocking brick

Info

Publication number: WO2008059544A1
Application number: PCT/IT2007/000701
Authority: WO
Inventors: Michele Montanelli
Original assignee: Michele Montanelli
Priority date: 2006-11-14
Filing date: 2007-10-05
Publication date: 2008-05-22
Also published as: ITMI20062182A1

Abstract

The invention concerns an interlocking brick (1) that comprises an upper face (2) and a lower face (4) in turn comprising grooves (6). The brick also comprises four side faces comprising at least one fixing portion (8) equipped with a flare (12). Finally, the brick comprises at least one through hole (14) comprising an opening on the upper face (2) and an opening on the lower face (4). The brick is characterised in that the flare (12) is V- shaped and the through hole (14) has a circular section.

Description

DESCRIPTION "IMPROVED INTERLOCKING BRICK"

The object of the present invention is an interlocking brick for simplified construction of masonry walls. Conventional bricks, known for a long time and widely- used in the construction of masonry walls, are valued for their simplicity of production and for their low cost. However, they are not without drawbacks. In masonry, each brick is linked to the others that surround it by means of mortar. The mortar must therefore be laid precisely, in uniform layers along each course of bricks so that the wall is vertical (or "perpendicular") and so that each course of bricks is horizontal (or "level") . This is usually performed manually. The laying of conventional bricks therefore requires highly qualified workmen.

Interlocking bricks have been proposed that allow laying to be simplified in order to overcome the greatest drawbacks of conventional monolithic bricks. Italian patent IT 1 129 828 to the same inventor, describes for example an interlocking brick that allows the wall to be laid dry. Such a brick is made so as to simulate, at least on one face, the appearance of a conventional brick. The brick also comprises recesses and channels that, once laying is complete, constitute a continuous network of vertical and horizontal channels between the bricks. Therefore, once the laying of the bricks is complete, a cast of cement at the top of the wall allows all of the channels to be filled up to the base consolidating the masonry wall. Such a wall, whilst being extremely simple to build, ensures an aesthetic effect substantially comparable to the widely appreciated appearance of a wall made from conventional bricks . The brick described in IT 1 129 828, although widely esteemed, is not without drawbacks. Indeed, it has a somewhat complex structure that requires extremely accurate production. Moreover, it requires a large number of special pieces intended for use in the ends of the masonry wall, in the corners, in the columns, etc.

Production of the complete line of bricks described by IT 1 129 828 is therefore extremely expensive. The purpose of the present invention is to devise and provide an improved interlocking brick that allows the aforementioned drawbacks with reference to the prior art to be at least partially avoided.

In particular, the task of the present invention is to provide an improved interlocking brick that allows cost- effective production. Such a purpose and such tasks are accomplished through a brick in accordance with claim 1.

Further characteristics and advantages of the brick according to the invention shall become clearer from the following description of preferred embodiments, given for indicating and not limiting purposes, with reference to the attached figures, in which:

- figure 1 illustrates a perspective view of a brick known from IT 1 129 828;

- figure 2 illustrates a plan view of the brick of figure 1;

- figure 3 illustrates a plan view of a first type of brick according to the invention;

- figure 4 illustrates a section along the line IV-IV of figure 3 ; - figure 5 illustrates a plan view of the detail of two bricks of figure 1 brought together;

- figure 6 illustrates a plan view of a second type of brick according to the invention;

- figure 7 illustrates a plan view of a third type of brick according to the invention;

- figure 8 illustrates a plan view of a fourth type of brick according to the invention;

- figure 9a illustrates a plan view of an odd course of bricks according to the invention to form a wall of a first type; - figure 9b illustrates a plan view of an even course of bricks according to the invention to form a wall of a first type;

- figure 10a illustrates a plan view of an odd course of bricks according to the invention to form a wall of a second type;

- figure 10b illustrates a plan view of an even course of bricks according to the invention to form a wall of a second type; - figure 11 illustrates a plan view of a course of bricks according to the invention to form a column of a first type;

- figure 12 illustrates a plan view of a course of bricks according to the invention to form a column of a second type;

- figure 13a illustrates a plan view of an odd course of bricks according to the invention to form a wall of a third type;

- figure 13b illustrates a plan view of an even course of bricks according to the invention to form a wall of a third type;

- figure 14 illustrates a perspective view of a pin suitable for use with a brick according to the invention; - figure 15 illustrates a side view of the pin of figure 14;

- figure 16 illustrates a plan view of the pin of figure 14;

- figure 17 illustrates a section along the line XVII- XVII of figure 16;

- figure 18 illustrates a section view of two bricks according to the invention laid on top of one another and joined through pins.

With reference to the aforementioned figures, a brick according to the invention has been wholly indicated with 1. The description of the brick 1 according to the invention shall be made hereafter with continuous comparison to the brick 1' known from IT 1 129 828 of which it represents a radical evolution. Similar elements of the two bricks shall be indicated with the same reference numerals, apart from that the elements of the known brick shall be marked with an apostrophe . The brick 1 according to the invention comprises, in a per se known way, an upper face 2 and a lower face 4. The lower face 4 is intended to be rested on other analogous bricks, apart from the first course of bricks that shall rest upon a different foundation. Respectively, the upper face 2 is intended to have other analogous bricks rested upon it, apart from the last course of bricks that shall have a different coping on top.

The upper and lower faces 2, 4 comprise grooves 6. The brick 1 comprises four other side faces. In accordance with the types of bricks according to the invention represented in figures 3, 6 and 7, the four side faces comprise two larger faces and two smaller faces. Such types shall be indicated hereafter with Ia, Ib and Ic respectively. In accordance with the type of bricks according to the invention represented in figure 8, the four side faces are all the same as each other and are the same as the larger faces of the previous types of bricks. Such a type shall be indicated hereafter with Id. At least one fixing portion 8, intended to have another analogous brick beside it, can be defined on the side faces .

In accordance with an embodiment , the remaining part of the side faces, i.e. the one that is not part of the fixing portion 8, is a so-called in-sight portion 10. This portion, when the wall in complete, is intended to be visible.

The fixing portion 8 comprises a V-shaped flare. In other words, the flare 12 is obtained by cutting the fixing portion 8 of the brick 1 along two planes that meet to form a dihedron.

As can be seen in figures 1 and 2, the known brick 1' also comprises a fixing portion 8' having a flare 12' . However, the flare 12' is not V-shaped but is vaguely U- shaped. In other words it cannot be obtained by cutting the fixing portion 8' of the brick 1' along just two planes, but it is necessary to cut it along a complex surface made up of at least three planes. Such a U-shaped cutting process therefore requires the use of complex and therefore expensive processing techniques, like for example slotting or milling in many steps .

The V-shaped flare 12, on the other hand, can be made much more simply through milling along the planes of the dihedron.

There are at least two in-sight portions 10, arranged on two opposite side faces of the brick 1. The in-sight portions 10 have a suitable finish so that they are pleasing to the eye. In accordance with an embodiment, the in-sight portions 10 comprise a relief 11 suitable for giving the masonry an effect known as ashlar. In accordance with other embodiments and in order to satisfy particular requirements, the in-sight portions 10 can comprise different aesthetic solutions, they can for example simulate the irregular surface of a traditional hand-made brick, etc.

The brick known 1 ' , as can be seen in figure 2 , comprises a single in-sight portion 10' arranged on just one side face. Such a characteristic is particularly disadvantageous because the bricks are typically exposed to the real possibility of being ruined during all of the moving steps that follow one after the other from firing in the brick-kiln to definitive arrangement in the masonry wall. A known brick 1' that has suffered damage to just the in-sight portion 10' can no longer be used and must therefore be discarded.

On the other hand, a brick 1 according to the invention that has suffered damage to an in-sight portion 10 can be used by turning it so as to expose the in-sight portion 10 opposite the ruined one. In other words, the brick 1 according to the invention is reversible and allows a reduction of waste close to 50%. The brick 1 according to the invention also comprises at least one through hole 14 that has a first opening on the upper face 14 and a second opening on the lower face 4.

As can be seen in figure 3, the through hole 14 has a circular section and can therefore be obtained through a common drill. As can be seen in figures 1 and 2, the known brick 1' also comprises a through hole 14 ' . The through hole 14 ' , however, does not have a circular section, but a vaguely- quadrangular section. In other words, it cannot be obtained by drilling, but to produce it a cut must be made along a complex surface consisting of at least four planes .

Such a process therefore requires the use of complex and therefore expensive processing techniques, like for example slotting or milling in many steps.

The through hole 14 with circular section can, on the other hand, be made much more simply through drilling. In accordance with an embodiment, the brick according to the invention also comprises at least two seats 16 on each of the two upper and lower surfaces 2, 4. The seats 16 are suitable for receiving suitable pins 18 that shall be described hereafter. The pins 18 and the seats 16 on the supporting surfaces of the bricks 1, allow each brick to interlock with the bricks that support it and with those that lie on top of it, as can be appreciated from the section of figure 18. In accordance with an embodiment, the seats 16 of the upper face 2 and the seats 16 of the lower face 4 are connected together to form a single channel that runs through the bricks 1. As can be seen in figure 3, the seats 16, when present, have a circular section and can therefore be obtained through a common drill.

As can be seen in figures 1 and 2, the known brick 1' also comprises seats 16' . However, the seats 16' do not have a circular section but an oval or elliptical section. In other words, they cannot be obtained by drilling, but to produce them more complex and expensive processing techniques must be carried out, like for example slotting or milling in many steps.

The seats 16 with circular section can, on the other hand, be made very simply through drilling. In the known brick 1', the seats 16' are oval or elliptical in shape to allow the necessary tolerance for the assembly of the bricks. Indeed, the seats 16' allow slight mobility of each brick 1' with respect to those that support it and/or that lie on top of it . Such an effect, in accordance with the present invention, is obtained by means of the tapered shape of the pins, a shape that can be clearly seen in figures 14, 15 and 17. Such a shape, unlike the known right cylinder shape, allows the pin 18 to be inclined with respect to the nominal position coaxial to the seat 16. Such an inclination allows the bricks to be slightly shifted, if needed, during laying to deal with inevitable imperfections.

As can be seen in figures 14 to 18, the pins 18 according to the invention comprise a tubular core surrounded by tapered radial fins . The invention, in order to allow every possible constructive solution, comprises different types of bricks 1, as outlined above, intended for different uses . Figures 3 to 5 represent, amongst the bricks 1 according to the invention, the most common type Ia, i.e. the one intended to have other bricks according to the invention next to it. The brick Ia comprises two opposite fixing portions 8 on the two smaller side faces. It also comprises two opposite in-sight portions 10 on the two larger side faces .

Figures 5, 9, 10 and 13 show plan views of examples of laying of the bricks Ia. In particular, figures 5 and 9 show a masonry wall that is 12.5 cm thick; figures 10 show a masonry wall that is 12.5 cm thick with a reinforcing pilaster or column 25 x 25 cm embedded in the thickness of the wall; and figures 13 show a double wall of 37.5 cm overall thickness, with a gap of 12.5 cm and with a structural connection between one wall and the other. Figure 6 represents, amongst the bricks 1 according to the invention, the type Ib intended to finish a single course and thus to potentially expose two larger side faces and a smaller side face. The brick Ib comprises a single fixing portion 8 on one of the two smaller side faces. It also comprises three in-sight portions 10 on the two larger side faces and on the remaining smaller side face.

Figures 9 and 12 show plan views of examples of laying of the bricks Ib. In particular, figures 9 show the angle of a masonry wall that is 12.5 cm thick; and figure 12 shows a hollow column of 37.5 x 37.5 cm. Figure 7 represents, amongst the bricks 1 according to the invention, the type Ic intended to finish a double course and thus to potentially expose two smaller side faces and a larger side face. The brick Ic comprises a single fixing portion 8 on one of the two larger side faces. It also comprises three in-sight portions 10 on the two smaller side faces and on the remaining larger side face. Figures 10b and 11 show plan views of examples of laying of the bricks Ic. In particular, figure 10b shows a masonry wall that is 12.5 cm thick with a reinforcing pilaster or column of 25 x 25 cm embedded in the thickness of the wall; and figure 11 shows a simple column of 25 x 25 cm. Figure 8 represents, amongst the bricks 1 according to the invention, the type Id intended to create a projection from one course and thus to potentially expose two entire side faces and half of the remaining side faces . The brick Id comprises two fixing portions 8 on half of two opposite side faces. It also comprises four in-sight portions 10 on the remaining halves of the two side faces and on the remaining side faces . Figures 10a and 13 show plan views of examples of laying of the bricks Id. In particular, figure 10a shows a masonry wall that is 12.5 cm thick with a reinforcing pilaster or column of 25 x 25 cm embedded in the thickness of the wall; and figures 13 show a double wall of 37.5 cm overall thickness, with a gap of 12.5 cm and with a structural connection between one wall and the other .

As shown by the examples of figures 9 to 13, the brick 1 according to the invention, thanks to just the four types described above, allows all of the types of masonry wall that can be made with conventional monolithic bricks to be made. In all of the types of masonry wall made, no portion of the bricks 1 that is not one of the in-sight portions 10 expressly intended to be exposed is exposed. The known brick 1' comprises a full thirteen different types. The man skilled in the art can immediately appreciate the logistical and economic advantage that derives from the drastic reduction in types of brick. Hereafter, the per se known method for laying the brick 1 according to the invention is described.

On a suitable foundation (flat and regular) a first course of bricks is laid side by side by the respective fixing portions 8. In the case in which the seats 16 are present, a pin 18 is inserted into each of them. A second course of bricks is laid on top of the first, taking care to place each brick of the second course straddling the two adjacent bricks of the first course. In this way, the pins of the seats 16 of the upper faces of the bricks of the first course are received in the seats 16 of the lower faces of the bricks of the second course (see figure 18) .

Each subsequent odd course shall on the whole repeat the arrangement of bricks of the first course and, similarly, each subsequent even course shall on the whole repeat the arrangement of bricks of the second course. Upon completion of the laying, a dry structure is obtained that is aesthetically identical to what will be the definitive masonry wall but that must be consolidated on the inside. Upon completion of the laying, inside the structure consisting of bricks 1, a network of vertical and horizontal ducts will have formed.

The vertical ducts are formed from the succession of through holes 14 (which have a circular section) and of recesses consisting of each pair of V-shaped flares 12 of two adjacent bricks. Such recesses, as can be seen in figure 5, are quadrangular shaped.

The horizontal ducts are formed from the succession of grooves 6 laid on top of one another in pairs as can be seen in figure 18.

The network of ducts allows the mortar, cast from above in very fluid state, to run and permeate the entire dry- structure. In this way the mortar, consolidating, makes the masonry wall cohesive. The network of ducts also allows the masonry wall to be reinforced with a suitable metallic armature, for example if the design requires that specific seismic protection criteria be satisfied. Indeed, the metallic armature makes the masonry wall elastic and resistant to dynamic loads.

The metallic armature can be easily arranged in the dry structure before casting the mortar. In particular, the horizontal armature can be laid in the grooves 6 of a course of bricks before laying the next course, whereas the vertical armature can be inserted from above along the vertical ducts formed by the through holes 14 and the flares 12.

The special V shape of the flares 12, as well as allowing them to be made more easily, allows vertical ducts with a large section to be obtained in which the maximum size of the "V" can be much greater than the maximum width of the "U" without weakening the brick 1. Such a width of the V-shaped flare allows the mortar to be taken into areas further towards the outside (i.e. closer to the outer surface) than can be obtained with the old U-shaped flares 12' . The presence of consolidated mortar near the outer surface of the wall considerably increases its resistance to possible stresses perpendicular to the surface of the wall. In accordance with an embodiment, the brick 1 according to the invention is made of tile. In this case it is preferably made by:

- Preparing a mixture consisting essentially of clay and water ; - Obtaining from the mixture the rough shape of the brick;

- Firing the rough-shaped brick in the kiln; and lastly

- Performing the required processes to obtain flares 12, through hole 14 and, eventually, seats 16. This is the preferred method to obtain the brick 1 in tile. However, there are other possible methods like the ones described below.

In accordance with other possible embodiments, the brick 1 according to the invention is made of non-tile material such as glass, cement, polymers and other different material suitable for the specific characteristics. In this case the brick is made by:

- Casting the fluid material into a mould suitable to give the brick 1 its final shape; - waiting for the material to harden; and

- Removing the brick 1 from the mould.

Regardless of the methods of production and material used, all bricks 1 according to the invention must have the shapes described above, in order to be interchangeable and compatible with each other.

Bricks 1, according to the invention, made of glass or polymers hinder, for example, absorption of humidity by the wall . This allows to make the first layer using glass or polymer bricks which prevent the capillarity phenomenon and provide an impermeable barrier against humidity rising from the ground. The subsequent layers can be made using analogous clay or cement bricks. Same bricks 1 according to the invention made of glass or polymers allow building swimming pools and tubs without extra linings to separate the masonry wall from the water.

Furthermore, bricks 1 according to the invention made of glass or transparent polymer allow building walls, even bearing walls, which allow entry of light. When building walls meant to allow entry of light, the masonry wall can be made of glass or polymer bricks. The masonry can be reinforced by casting a transparent resin instead of the conventional cement mortar. Such resin can be cast in a fluid state and, polymerizing in loco, it guarantees cohesion of the masonry analogously to the action of the cement mortar. Resins suitable for such uses can be, for example, epoxy resin known per se, or other resins which allow meeting specific requirements. Bricks 1, according to the invention, made of cement allow to obtain a wide range of aesthetic and chromatic combinations. Currently, as a matter of fact, there is a variety of effective colouring, decoration and finishing methods and such methods can be applied on the cement used to make the bricks 1. Regardless of the material and the method of production used, the bricks 1, according to the invention are preferably rectified. In other words, upon completion of the works which give the bricks 1 the final shape, it is preferable to mill in a controlled manner the upper face 2 and/or the lower face 4, and/or the anchoring portions 8 of the lateral faces of the bricks 1. Such rectification guarantees both parallelism between the opposite faces of a single brick and uniformity of the dimensions of all bricks 1 of a single line, regardless of the lot, the material and or method of production.

The dimensions guaranteed by the rectification can be the standard dimensions provided for by the UNI specifications or other dimensions predefined by the manufacturer and applied on the entire line of bricks. A man skilled in the art can make modifications and adaptations to the brick described above and can replace elements with other functionally equivalent elements, in order to satisfy contingent requirements, without departing from the scope of the following claims. Each of the characteristics described as belonging to a possible embodiment can be made independently of the other embodiments described.

Claims

1. Interlocking brick (1) comprising:

- an upper face (2) and a lower face (4) comprising grooves (6) ; - four side faces comprising at least one fixing portion (8) equipped with a flare (12) ; and

- at least one through hole (14) comprising an opening on said upper face (2) and an opening on said lower face (4); characterised in that:

- said flare (12) is V-shaped; and

- said through hole (14) has a circular section.

2. Brick (1) according to the previous claim in which the V-shaped flare (12) is obtained by cutting the fixing portion (8) of the brick (1) along two planes that meet to form a dihedron.

3. Brick (1) according to any one of the previous claims in which said side faces also comprise at least two insight portions (10) intended to be visible when the masonry wall is complete.

4. Brick (1) according to the previous claim in which said at least two in-sight portions (10) are arranged on two opposite side faces of the brick (1) .

5. Brick (1) according to claim 3 or 4 in which said in- sight portions (10) comprise a relief (11) suitable for giving the masonry wall an ashlar effect.

6. Brick (1) according to any one of claims 3 to 5 in which the in-sight portions (10) comprise an irregular surface that simulates a traditional handmade brick.

7. Brick (1) according to any one of the previous claims also comprising at least two seats (16) on each of said upper and lower surfaces (2, 4).

8. Brick (1) according to the previous claim also comprising pins (18) and in which said seats (16) are suitable for receiving said pins (18) .

9. Brick (1) according to the previous claim in which said pins (18) and said seats (16) allow each brick (1) to interlock with the bricks that support it and with those that lie on top of it.

10. Brick (1) according to any one of claims 7 to 9 in which a seat (16) of the upper face (2) and a seat (16) of the lower face (4) are connected together to form a single channel that runs through the brick (1) .

11. Brick (1) according to any one of claims 7 to 10 in which the seats (16) have a circular section.

12. Brick (1) according to any one of claims 8 to 11 in which said pin (18) has a tapered shape suitable for allowing the pin (18) to be laid in the seat (16) inclined with respect to the nominal position coaxial to the seat (16) .

13. Brick (1) according to any one of claims 8 to 12 in which said pin (18) comprises a tubular core surrounded by tapered radial fins.

14. Brick (la) according to any one of the previous claims comprising two opposite fixing portions (8) on two smaller side faces; and two opposite in-sight portions (10) on two larger side faces.

15. Brick (Ib) according to any one of claims 1 to 13 comprising a single fixing portion (8) on a smaller side face; and three in-sight portions (10) on two larger side faces and on a smaller side face.

16. Brick (Ic) according to any one of claims 1 to 13 comprising a single fixing portion (8) on a larger side face; and three in-sight portions (10) on two smaller side faces and on a larger side face.

17. Brick (Id) according to any one of claims 1 to 13 comprising two fixing portions (8) on half of two opposite side faces; and four in-sight portions (10) on the remaining halves of the two side faces and on the remaining side faces.

18. Brick (l) according to any one of the preceding claims in which said brick is made of tile.

19. Brick (1) according to any one of the preceding claims in which said brick is made of glass.

20. Brick (1) according to any one of the preceding claims in which said brick is made of cement .

21. Brick (1) according to any one of the preceding claims in which said brick is made of polymer.

22. Brick (1) according to any one of the preceding claims in which said brick is rectified.

23. Masonry wall comprising a plurality of bricks (1) according to any one of the previous claims.

24. Masonry wall according to the previous claim comprising a network of vertical and horizontal ducts.

25. Masonry wall according to the previous claim in which said vertical ducts are formed from the succession of through holes (14) and the recesses consisting of each pair of V-shaped flares (12) .

26. Masonry wall according to claim 24 or 25 in which said horizontal ducts are formed from the succession of said grooves (6) .

27. Masonry wall according to any one of the claims 24 to 26 also comprising a cast of cement mortar in said network of ducts .

28. Masonry wall according to any one of claims 24 to 27 also comprising a metallic armature in said network of ducts .