WO2011058309A1

WO2011058309A1 - Building block and production thereof

Info

Publication number: WO2011058309A1
Application number: PCT/GB2010/002068
Authority: WO
Inventors: John E. Gray
Original assignee: Gray John E
Priority date: 2009-11-10
Filing date: 2010-11-10
Publication date: 2011-05-19
Also published as: EP2499307A1; NZ600423A; GB0919626D0; AU2010317787A1

Abstract

A method of moulding from solidifiable material a building block (101 ) comprised of parallel walls (102-105) that are transversely spaced from each other so that adjacent walls have opposed inner surfaces and further comprised of at least one cross-wall (106-108) which connect said opposed inner surfaces of the parallel walls (102-105) and which incorporates between its end regions a recess (116) extending across the width of the cross-wall. The method comprises introducing the solidifiable material into a mould (200) in which the upper surfaces of the parallel walls (102-105) and the end regions of the cross-wall (106-108) are formed in open- topped portions of the mould (200), effecting compaction of the solidifiable material through said open-topped regions, and solidifying said material.

Description

Building Block and Production Thereof

The present invention relates to a building block and more particularly (but not necessarily exclusively) to such a block for use in constructing a dry-stacking high performance masonry wall. The invention also relates to a method of producing the block.

More specifically, the invention relates to a one piece integrally moulded (or cast) building block used for producing a wall with internal voids. More particularly, the block is of the type comprised of parallel walls that are transversely spaced from each other so that adjacent walls have opposed inner surfaces and further comprised of at least one cross-wall connecting the opposed inner surfaces of the parallel walls.

One example of such a prior art construction of block is disclosed in EP-A-1 120 505 (J.E. Gray) and is illustrated in Figs 1 and 2 of the drawings accompanying the present specification. As shown in the plan view of Fig 1 , a building block 1 disclosed in EP-A-1 120 505 comprises:

(i) first and second outer walls 2 and 3 respectively which are transversely spaced from each other;

(ii) first and second inner walls 4 and 5 respectively which are provided between, and respectively adjacent to, the first and second outer walls 2 and 3 and which are transversely spaced therefrom and from each other whereby any pair of adjacent walls 2, 3, 4 and 5 have spaced facing surfaces;

(iii) a first set of three cross-walls 6 connecting the opposed inner surfaces of outer and inner walls 2 and 4,

(iv) a second set of three cross-walls 7 connecting the inner surfaces of the second outer and inner walls 3 and 5; and

(v) a third set of two cross-walls 8 connecting the facing surfaces of the inner walls 4 and 5 to each other. As will be seen in Fig 1 , the cross-walls 6 and 7 are provided one at each end of the block 1 and one centrally thereof whereby two voids 9 are defined between each adjacent pair of inner and outer walls. The two cross-walls 8 are provided at the quarter points of the length of the block so that a void is defined between the inner walls 4 and 5 of the block together with two "part-voids" 1 1 which are open at the ends of block 1.

All cross-walls 6-8 are formed in their upper surface with a V-shaped notch 12 - see Fig 2 which is a view looking in the direction of arrow X of Fig 1 . As shown in Fig 2, the V-shaped notch extends downwardly from the level of the upper surfaces of the various walls 2-6. Similarly for the notches in cross-walls 7 and those in cross- walls 8.

Further features of the illustrated block are that the upper surfaces 13 of the outer walls 2 and 3 are below the level of the upper surfaces 14 of the inner walls 4 and 5. The upper surfaces 13 (of outer walls 2 and 3) are provided with bosses 25 which at their tops are level with upper surfaces 14 (of inner walls 4 and 5).

Additionally vertical rebates 26 are provided in the outer walls 2 and 3 at each side edge thereof.

The manner in which blocks 1 are laid to construct a wall is described fully in EP-A-1 120 505. Briefly however the blocks of any one course are laid end-to-end so that the "part-voids" 11 of two blocks form a "full void" similar to voids 9 and 10. Blocks 1 in successive courses are half-bonded relative to those in the vertically adjacent course so that the voids are in vertical alignment.

The bosses 25 provide for stability during dry-stacking of the blocks 1 and serve also to define horizontal bed joints, vertical (or "perp") joints being defined by the rebates 26.

At various levels within the wall, horizontal concrete beams will be cast in situ in the notches 12 which, for this purpose, will also receive reinforcing bars. The blocks 1 may be of concrete and are cast in a mould sub-divided into four chambers (one for forming each of the walls 2-5) by three partitions. These partitions are associated with passageways to provide communication between adjacent sub- chambers to allow formation of the cross-walls 6-8 in conjunction with. V-shaped profiles provided within the upper regions of the passageways for producing the V- shaped notches 12. In the moulding operation, concrete (or other solidifiable material) is introduced into each of the four sub-chambers through rectangular aperatures in a surcharge plate, these rectangular apertures registering with the upper rectangular openings of the sub-chambers. Subsequently the concrete in the sub-chambers is compressed using means which are of the same rectangular size as the sub-chambers.

The method described in the previous paragraph has been found suitable for making low volumes of blocks but not entirely suitable for high volume manufacture since it has been found that concrete (or other solidifiable material) would not fill the mould to form the cross-walls 6-8 with their V-shaped notches 12. This is a disadvantage because the cross-walls 608 are the structure that connects the parallel walls 2-6 in the manner described above. With insufficient concrete (or other solidified material) in the cross-walls 6-8 then the structural integrity of the block is compromised.

It is therefore an object of the present invention to obviate or mitigate the above mentioned disadvantages.

According to a first aspect of the present invention there is provided a method of moulding from solidifiable material a building block comprised of parallel walls that are transversely spaced from each other so that adjacent walls have opposed inner surfaces and further comprised of at least one cross-wall connecting said opposed inner surfaces of the parallel walls, the upper surface of the cross-wall incorporating between its end regions a recess extending across the width of the cross-wall, the method comprising introducing the solidifiable material into a mould in which the upper surfaces of the parallel walls and the end regions of the cross-wall are formed in open portions of the mould, effecting compaction of the solidifiable material through said open regions, and solidifying said material. By way of definition, the upper surfaces of the parallel walls are those surfaces (also know as bed surfaces) which are uppermost when the block is laid and not necessarily upper surfaces when formed in the mould.

We have established, in accordance with the invention, that producing the block in a mould in which the end regions of the cross-wall are formed in open- topped portions of the mould which are subjected to compaction has the advantage that the cross-walls may be fully formed during high volume production. Additional solidifiable material (e.g. concrete) may be provided at the end regions of the cross- wall as compared to a similar prior art block formed by the procedure described above with V-shaped notches. This additional material is compacted through the open-topped portions of the mould forming the end regions of the cross-wall and ensures that solidifiable material is available completely to form the recessed section of the cross-wall.

In a preferred embodiment of the method, the end regions of the cross-wall are compacted wholly below the upper surfaces of the parallel walls. This leads to a further (second) aspect of the present invention according to which there is provided a one piece integrally moulded building block comprised of parallel walls that are transversely spaced from each other so that adjacent walls have opposed inner surfaces and further comprised of at least one cross-wall connecting said opposed inner surfaces of the parallel walls, the cross-wall incorporating intermediate its end regions a recess in its upper surface wherein the end regions of the cross-wall are compacted wholly below the upper surfaces of the parallel walls.

In a preferred embodiment of the invention, the upper surfaces of the end regions of the cross-wall are flat and extend perpendicularly to the major faces of the parallel walls. Typically the upper surface of the end region of the cross-wall will be about 23-27mm below the upper surfaces of the top walls for a block having a depth of 100mm.

Generally the lower surfaces of the cross-wall will be flush with the lower surfaces of the parallel walls. The recess in the cross-wall may be semi-circular along its length although other configurations (e.g. U-shape) are possible.

A first embodiment of blocks in accordance with, and produced by the method of, the present invention may comprise:

(i) first and second outer walls transversely spaced from each other;

(ii) first and second inner walls provided between and respectively adjacent to, the first and second outer walls and being transversely spaced therefrom and from each other;

(iii) a first set of three said cross-walls connecting the first inner and outer walls, and a second set of three said cross-walls connecting the second inner and outer walls, the cross-walls of each set being provided one at each end of the block and one centrally thereof whereby two voids are defined between each adjacent pair of inner and outer walls; and

(iv) a third set of two cross-walls connecting the inner walls to each other, the two cross-walls of the third set being provided at the quarterpoints of the length of the block so that a void is defined between the inner surfaces of the block.

An example of a block in accordance with this first embodiment of the invention is illustrated in Figs 3-8 of the accompanying drawings.

A block in accordance with this first embodiment of the invention may be produced in a mould as defined in claim 15.

A second embodiment of block in accordance with, and produced by the method of, the present invention may comprise:

(i) first and second outer walls transversely spaced from each other; (ii) first and second inner walls provided between and respectively adjacent to, the first and second outer walls and being transversely spaced therefrom and from each other;

(iii) a first set of two said cross-walls connecting the first inner and outer walls, and a second set of two said cross-walls connecting the second inner and outer walls, the cross-walls of each set being provided one at each end of the block whereby a void is defined between each adjacent pair of inner and outer walls; and

(iv) a said cross-wall connecting the inner walls to each other centrally of the block.

An example of a block in accordance with this first embodiment of the invention is illustrated in Figs 29-30 of the accompanying drawings.

A block in accordance with this first embodiment of the invention may be produced in a mould as defined in claim 17.

Blocks in accordance with the first and second embodiments of the invention may be formed such that:

(a) the upper surfaces of the first and second outer walls are below the level of the upper surfaces of the first and second inner walls; and

(b) the upper surfaces of the first and second outer walls are provided with bosses which at their tops are level with the upper surfaces of the first and second inner walls.

The bosses provide for stability during dry-stacking of the blocks and also serve to define horizontal bed joints.

Alternatively or additionally blocks in accordance with the second embodiment of the invention may be formed such that vertical rebates are provided in the outer walls at each side edge thereof. These vertical rebates serve to define vertical (or "perp") joints in walls constructed from the block. Blocks in accordance with the invention will preferably be produced from concrete although we do not preclude the possibility of using other solidifiable materials.

The invention will be further described by way of example only with reference to the accompanying drawings, in which:

Fig 1 is a plan view of a building block as disclosed in EP-A-1 120 505;

Fig 2 is an end view of the building block illustrated in Fig 1 ;

Fig 3 is a plan view of a first embodiment of building block in accordance with the invention;

Figs 4-7 are sectional views on lines A-A, B-B, C-C and D-D respectively of

Fig 3;

Fig 8 is an end view of the block illustrated in Fig 3;

Fig 9 is a perspective view of a mould (with surcharge plate removed) for producing a block as illustrated in Fig 3;

Fig 10 is a perspective view of the mould shown in Fig 9 with surcharge plate in position;

Fig 1 1 illustrates the sequence of moulding operations to produce the block of

Fig 3;

Fig 12 schematically illustrates an ejector plate as used in the procedure of

Fig 10;

Fig 13 illustrates a stage in the moulding operation;

Fig 14 is a plan view of a second embodiment of block in accordance with the invention for forming a corner in a construction produced from the blocks of Fig 3; Fig 15 is an end view of the block shown in Fig 13;

Figs 16-20 are respectively sections on lines E-E, F-F, G-G, H-H and J-J of the block shown in Fig 14;

Figs 21-28 are similar to Figs 14-20 but for a third embodiment of block which is of opposite hand to that illustrated in Fig 14;

Fig 29 is a plan view of a fourth embodiment of block in accordance with the invention;

Fig 30 is an end view of the block shown in Fig 29;

Figs 31-32 are respectively sections on lines Q-Q and R-R of the block shown in Fig 29; and

Fig 33 shows a modification of the block illustrated in Fig 4.

The salient points of the prior art block shown in Figs 1 and 2 have been outlined above so further detailed description of the block will not be given but may be obtained by reference to EP-A-1 120 505.

Fig 3 is a plan view of a first embodiment of block 101 in accordance with the invention and will be seen to be of similar construction to the prior art block of Fig 1. Therefore for convenience those parts of the block in Fig 3 which have a corresponding part in the block of Fig 1 are given the same reference numeral plus 100. Thus, for example, an outer wall of block 101 is referenced as 102 and corresponds with outer wall 2 of block 1. The principal difference between the blocks illustrated in Figs 1 and 3 lies in the configuration of the top surfaces of the cross- walls 106-108. As illustrated in Fig 4 the cross-walls 106-108 have upper surfaces that lie wholly below the bed surfaces 102a-105a of the walls 102-105 and are configured so as to have end regions 115a and 115b extending perpendicularly to the major surfaces of walls 102-105 with an intermediate recess 116 which extends across the entire width of the cross-wall. Each recess 116 is generally semi-circular when viewed in a direction looking along the length of block 101 , i.e. in the direction of arrow Z of Fig 3.

The recesses 116 of cross-walls 106 are aligned with each other. Similarly for the recesses 116 of cross-walls 107 and 108.

Reference is now made to Fig 9 which illustrates a mould assembly 200 (with surcharge plate omitted) intended for use in producing a plurality of blocks 101 of the type illustrated in, and described with reference to, Fig 3. Mould assembly 200 comprises a plurality of individual moulds 201 each for producing an individual block 101. For the purposes of clarity, only one mould 201 has been illustrated completely but it will be appreciated that all moulds 201 in the assembly 200 of the same construction.

In more detail, mould 201 comprises a bounding, quadrilateral-shaped frame 215 which is open at both the top and bottom. Provided within frame 215 are three rows of blocks 216-218 which (in the manner illustrated in Fig 9) subdivide the mould into sub-cavities 202-205 within which walls 102-105 respectively of block 101 are formed during a moulding operation. There are two blocks 216 positioned so as to define three passageways 219 providing communication between sub-cavities 202 and 204, these passageways 219 serving (during the moulding operation) to provide for formation of the three cross-walls 106. Similarly there are two blocks 218 positioned so as to define three passageways 220 which provide communication between sub-cavities 203 and 205, to provide for formation of the three cross-walls 107. Finally, there are three blocks 217 positioned to define two passageways 221 between sub-cavities 204 and 205 and thereby provide for formation of cross-walls 108.

It will be appreciated that the blocks 216-218 serve to form the various voids and "half-voids" 108-111 in the final block.

As illustrated in Fig 9, mould 201 incorporates three parallel, profiled bars 225. Each bar 205 extends along a respective row of blocks 216-218 (for which purpose the upper surfaces thereof are appropriately recessed to receive the bar) from one side of the frame to the other. As seen in cross-section, the profile bars 205 have upper, parallel sides and a lower, semi-circular end which (during the moulding operation) serves to form the recesses 116 in the cross-walls 106-108 of the block. More specifically it will be understood that it is the regions of the bars 225 which extend across (and therefore exposed within) the passageways 219-221 that serve this purpose.

To produce a block 101 , mould 201 is placed on an appropriate base and is overlaid with a surcharge plate arrangement 300 comprised of three generally rectangular ribs 301-303 which extend in the same direction as the blocks 216-218 (see Fig 10). Rib 301 generally overlies block 216 but has notches 301a located along one of its longitudinal edges and notches 301 b along the other edge. These notches 301a and 301 b are positioned in register with the upper ends of passageways 209 either side of the bar 225. Rib 303 is of the same shape as rib 301 and similarly has notches 303a and 303b in register with the upper ends of passageways 219 either side of the bar 225. Rib 302 follows the same principle but along each longitudinal edge has two notches 202a and 202b that overly the upper ends of passageways 219.

The mould assembly comprised of mould 200 and surcharge plate 300 as illustrated in Fig 10 is used in the sequence of operations illustrated in Fig 11 to produce a block 101. Concrete (or any other solidifiable material from which the bock is to be produced) is introduced into the mould assembly from the top thereof. Subsequently the concrete in the mould is compacted by compression from four ejector rails 401-404, each of which is in the form a main plate with an appropriate number (see below) of rectangular-section ridges 405 along one or both major surfaces thereof. The upper ends of ridges 405 are flush with the top edges of the respective plates on which they are provided but their lower ends 405a extend below the lower edge of the plate, as schematically illustrated in Fig 12 for ejector rail 401 , and provide compaction elements.

Ejector 401 has three ridges 405 which are dimensioned and positioned so as to be capable of passing through the notches 301a in rib 301. Ejector plate 404 is similar with ridges 405 provided on only one face of the plate and configured to pass through notches 303b in rib 303. Ejector plate 402 has ridges 405 on both faces, namely three ridges on one face for travel through the notches 301b of rib 301 and two ridges 405 on the opposite face for travel through recesses 302a of rib 302. Ejector plate 403 is of generally similar construction to ejector plate 402 and provided on one face with three ridges for travel through recesses 303a of rib 303 and two ridges on the opposite face for travel through recesses 302b of rib 302.

In order to effect compaction, ejector rails 401-404 are lowered relatively into the mould to a level such that the lower surfaces of rails 401-404 descend to a level for forming the bed faces 102a, 103a, 104a and 105a of the block 101 whereas the lower ends of ridges 405 form the upper surfaces 115a and 115b of the cross-walls in conjunction with the lower end of profile bar 225 which forms the semi-circular recesses 116, as illustrated in Fig 13.

The lower ends of ridges 405 are able to force concrete around the lower regions of profiled bar 205, thus ensuring that the moulded cross-walls are full and compact.

Once the required compaction has been completed, mould 200 may be lifted relatively off the base whilst ejector rails 401-404 remain in place and pass relatively through the mould (third step in Fig 10). Finally the finished block 101 is removed from the mould.

The moulding technique described above may be adapted to produce other embodiments of block in accordance with the invention. Thus, for example, the moulding technique may be used to produce the "corner block" 501 which is illustrated in self-explanatory Figures 14-20 or the corner block 601 of opposite hand illustrated in self-explanatory Figures 21-28.

In an alternative embodiment, a "half-block" in accordance with the invention may be as illustrated in self-explanatory Figures 29-32.

A further modification (in this case for the block shown in Fig 4) is illustrated in Fig 33. As seen (in somewhat exaggerated manner) in Fig 33, the facing surfaces of the first outer wall 102 and the first inner wall 104 flare downwardly towards each other. Similarly the facing surfaces of the second outer wall 103 and second inner wall 105 also flare downwardly towards each other. Finally the facing surfaces of the first inner wall 104 and second inner wall 105 also flare downwardly towards each other. This configuration assists in removal of the block from the mould.

Other modifications that may be made include changing the relative width, lengths and heights of the block as compared to the embodiments illustrated in the drawings.

It should also be appreciated that the block may be made of any suitable material, e.g. concrete or a more lighter weight material (e.g. comprised of lightweight aggregate).

Claims

1. A method of moulding from solidifiable material a building block comprised of parallel walls that are transversely spaced from each other so that adjacent walls have opposed inner surfaces and further comprised of at least one cross-wall connecting said opposed inner surfaces of the parallel walls, the upper surface of the cross-wall incorporating between its end regions a recess extending across the width of the cross-wall, the method comprising introducing the solidifiable material into a mould in which the upper surfaces of the parallel walls and the end regions of the cross-wall are formed in open-topped portions of the mould, effecting compaction of the solidifiable material through said open-topped regions, and solidifying said material.

2. A method as claimed in claim 1 wherein said end regions of the cross- wall are compacted to a level wholly below the level of the upper surfaces of the parallel walls.

3. A method as claimed in claim 2 wherein said end regions of the cross- wall extend perpendicularly to the opposed inner surfaces of the parallel walls.

4. A method as claimed in any one of claims 1 to 3 wherein the recess in the cross-walls is semi-circular along its length.

5. A method as claimed in any one of claims 1 to 4 for producing a building block comprised of:

(i) first and second outer walls transversely spaced from each other;

6. A method as claimed in any one of claims 1 to 4 for producing a building block comprised of:

(i) first and second outer walls transversely spaced from each other;

7. A method as claimed in claim 5 or 6 wherein the block is formed such that:

8. A method as claimed in any one of claims 5 to 7 wherein the block is formed such that vertical rebates are provided in the outer walls at each side edge thereof.

9. A method as claimed in any one of claims 1 to 8 wherein the solidifiable material is concrete.

10. A method as claimed in claim 5 wherein the facing surfaces of the first inner and outer walls flare downwardly towards each other, the facing surfaces of the second inner and outer walls flare downwardly towards each other and the facing surfaces of the first inner and second inner walls flare downwardly towards each other.

11. A one piece integrally moulded building block comprised of parallel walls that are transversely spaced from each other so that adjacent walls have opposed inner surfaces and further comprised of at least one cross-wall connecting said opposed inner surfaces of the parallel walls, the cross-wall incorporating intermediate its end regions a recess in its upper surface wherein the end regions of the cross-wall are compacted wholly below the upper surfaces of the parallel walls.

12. A block as claimed in claim 1 1 which comprises:

(i) first and second outer walls transversely spaced from each other;

(ii) first and second inner walls provided between and respectively adjacent to, the first and second outer walls and being transversely spaced therefrom and from each other; and

(iii) a first set of three said cross-walls connecting the first inner and outer walls, and a second set of three said cross-walls connecting the second inner and outer walls, the cross-walls of each set being provided one at each end of the block and one centrally thereof whereby two voids are defined between each adjacent pair of inner and outer walls.

13. A block as claimed in claim 1 1 which comprises (i) first and second outer walls transversely spaced from each other;

14. A block as claimed in claim 12 or 13 wherein the block is formed such that:

15. A block as claimed in any one of claims 12 to 14 which is formed such that vertical rebates are provided in the outer walls at each side edge thereof.

16. A block as claimed in any one of claims 12 to 15 wherein the facing surfaces of the first inner and outer walls flare downwardly towards each other, the facing surfaces of the second inner and outer walls flare downwardly towards each other and the facing surfaces of the first inner and second inner walls flare downwardly towards each other.

17. A mould for producing a block as claimed in claim 11 which comprises:

(a) first and second open-topped outer chambers transversely spaced from each other for forming said first and second outer walls,

(b) first and second open-topped inner chambers provided between and respectively adjacent to the first and second outer chambers and being transversely spaced therefrom and from each other, said first and second inner chambers being for forming said first and second inner walls,

(c) a first set of three cross-chambers connecting the first inner and first outer chambers, and a second set of three cross-chambers connecting the second inner and second outer chambers, the cross-chambers of the first and second sets being provided one at each end of the block and one centrally thereof, being open- topped at their end regions, being for forming said first and second sets of cross- walls respectively, and being internally configured to produce the recesses thereof, and

(d) a third set of two cross-chambers connecting the first and second set of inner chambers, the cross-chambers of the third set being provided at the quarterpoints of the length of the mould, being open-topped at their end regions, being for forming said third set of cross-walls, and being internally configured to produce the recesses thereof.

18. A method of producing a block as claimed in claim 12 the method comprising introducing solidifiabie material into a mould as claimed in claim 15 and effecting compaction of the solidifiabie material through the open-topped regions of the inner, outer and cross-chambers.

19. A mould for producing a block as claimed in claim 14 which comprises:

(a) first and second open-topped outer chambers transversely spaced from each other for forming said first and second outer walls, (b) first and second open-topped inner chambers provided between and respectively adjacent to the first and second outer chambers and being transversely spaced therefrom and from each other, said first and second inner chambers being for forming said first and second inner walls,

(c) a first set of two cross-chambers connecting the first inner and first outer chambers, and a second set of two cross-chambers connecting the second inner and second outer chambers being provided one at each end of the block, being open-topped at their end regions, being for forming said first and second sets of cross-walls respectively, and being internally configured to produce the recesses thereof, and

(d) a third cross-chamber connecting the first and second set of inner chambers, the third cross-chamber being provided centrally along the length of the mould, being open-topped at its end regions, being for forming said third cross-wall, and being internally configured to produce the recesses thereof.

20. A method of producing a block as claimed in claim 13 the method comprising introducing solidifiable material into a mould as claimed in claim 17 and effecting compaction of the solidifiable material through the open-topped regions of the inner, outer and cross-chambers.