Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: INTERLOCKING BLOCKS AND TILES FOR BUILDINGS.
FIELD:
The invention relates to buildings; to buildings made from a limited range of
modular
parts, and in particular to buildings made from interlockable modular parts
formed from a
plastics material by a rotational moulding process.
BACKGROUND
The inventor has previously described buildings, such as dwellings, made from
a plastics
material by a rotational moulding process in a large oven holding a heated
mould that is
rotated in one axis only, while feeding a flow of a selected type of plastics
granule (to set
solid or to set as a foam) into the interior of the mould. Such an overican
produce a round
building several metres in diameter and several metres off the ground, as a
single item.
The inventor has previously described unitary parts for buildings made of
fused plastics
by rotational moulding techniques but the shapes of the parts were generally
dictated by
the shape of the rotating oven and retained curved or circular forms, rather
than by
following the usual building conventions that seek rectangular or cubic
modules, like
bricks, for assembling rectangular buildings of unlimited size. For example,
in
WO/2008/133535 the Applicant described "a bell-shaped product capable of
conversion
into a dwelling is made in this manner inside a metal mould, open at one end
and slowly
rotating about a horizontal axis in an oven". That is a 2 metre diameter oven.
The prior-art finished structures retained dimensional limits of the rotating
ovens. In
W02010/036130 the present Applicant described a single-axis rotational
moulding
apparatus which conveniently forms planar or curved three-dimensional shapes
of
plastics, suitable as modules for buildings. An erectable, demountable
building made of
such modules may be shipped in the disassembled state and then erected by
untrained
personnel on a site. The modules may be made of wood or plastics. Preferred
modules are
made by rotational moulding and include insulation-filled cavities serving as
thermal
insulation. A further oven is used to fabricate large cylinders. After removal
the hot
cylinders are flattened into sheets of plastics material for use as flooring.
PROBLEM TO BE SOLVED:
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If the inventor's prior-art process could be modified so that it produced
moulded and
inter-joinable cubic structures resembling bricks or concrete blocks, a
builder could
construct a building having dimensions that "escape" the dimensions of the
oven.
OBJECT
35 An object of the present application is to provide a quickly, simply and
easily constructed
building at a site, or at least to provide the public with a useful choice.
SUMMARY OF INVENTION
In a first broad aspect, the invention provides interlockable components
comprising a
mutually interlockable set for use in building construction wherein each
component of the
40 set has an exterior comprised of a fused thermoplastics material and an
interior; each
component conforming to standardised dimensions at least with respect to a
=
complementary interlocking portion, the set of components including:
rectangular wall panels; the panels being interlockable in two perpendicular
axes;
rectangular outer wall panels having a domed external surface; the panels
being
45 interlockable in two perpendicular axes;
rectangular outer wall panels having an environmentally resistant external
surface; the
panels being interlockable in two perpendicular axes.
Preferably any interlockable component for use as part of a set as previously
described in
this section uses tongue and groove complementary joints having standardised,
50 compatible dimensions along mating edges of the component, said joints
comprising the
interlocking portions; said joints being capable of being joined together by
adhesive or
physical fastening means.
In a related aspect, a further range of components compatible with the
interlockable
component as previously described in this section are selected from a range
including:
55 interlockable corner pillars; interlockable rectangular full-height wall
panels;
interlockable elongated roof tile panels; window frames; door frames; panels
having an
integrated window within an aperture; panels having a gap into which a window
frame
may be inserted; and panels which when interlocked form a gap into which a
window may
be inserted.
60 In a major aspect, any interlockable component as previously described
in this section is
comprised of fused together thermoplastics granules having at least a first
composition;
the component having been melted together within a heated mould.
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In a first related aspect, an external layer of the component is entirely
comprised of a
fused mass formed by heating and melting a first selected composition
including a first
65 type of non-foaming type of thermoplastics granule within a heated mould
during rotation
of the mould; the external layer surrounding a void.
In an option of the first related aspect, a portion of the external layer of
the component is
comprised of a fused mass formed by heating and melting a second selected
composition
including a non-foaming type of thermoplastics granule within a heated mould
while not
70 fully rotating the mould; the external layer surrounding a void.
In a second related aspect the void within the component is optionally filled
with a fused,
foamed mass formed by subsequent introduction of a foaming type of
thermoplastics
granule into the heated mould so that, after moulding, the foamed mass is
contained
within a non-foamed external mass, together comprising the interlockable
component.
75 In a second broad aspect the invention provides a method for
manufacturing interlockable
building components; the method including the steps of:
creating an openable and releasable mould for each distinct shape of
component,
heating an oven to a working temperature,
loading each mould with an amount of a thermoplastics material preferably as
80 granules,
placing each mould in the oven while rotating the mould so that all parts of
the mould
are internally coated with the thermoplastics material,
after a time removing each mould and allowing it to cool,
opening the mould,
85 and optionally trimming each component so that its dimensions are
controlled.
In a third broad aspect the invention provides a interlockable range of
components; each
component having an exterior comprised of a fused thermoplastics material and
an
interior; each component conforming to standardised dimensions with respect to
a
complementary interlocking component, but in contrast to the first broad
aspect the
90 components are selected from a range of non-rectangular blocks including
a set of
components having a triangular outline and a set of components having a
hexagonal
outline; said blocks being interlockable by tongue and groove joining means
provided
along each of the edges.
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Preferably the components are held together at the joints with one or more of
the
95 following fastening means:
a) Physical fasteners which traverse the joint, thereby holding the components
to
each other,
b) Physical fasteners moulded into the joints, selected from a range including
mating
lugs and sockets,
100 c) Plastics glues selected from a range including solvent glues, two-
part glues such as
epoxies, and glues which become active when dried,
d) Localised application of heat, thereby locally melting the components on to
each
other, including heat from a heat gun, from an ultrasonic generator, from an
included hot wire, or from a reversibly penetrating hot object.
105 e) Preferably the physical fasteners are capable of being undone, so
that after a
period of use a fabricated building may be disassembled and removed.
PREFERRED EMBODIMENT
The description of the invention to be provided herein is given purely by way
of example
110 and is not to be taken in any way as limiting the scope or extent of
the invention.
Throughout this specification unless the text requires otherwise, the word
"comprise" and
variations such as "comprising" or "comprises" will be understood to imply the
inclusion
of a stated integer or step or group of integers or steps but not the
exclusion of any other
integer or step or group of integers or steps. Each document, reference,
patent application
115 or patent cited in this text is expressly incorporated herein in their
entirety by reference.
Reference to cited material or information cited in the text should not be
understood as a
concession that the material or information was part of the common general
knowledge or
was known in New Zealand or in any other country.
DRAWINGS
120 Fig 1: shows an oblique perspective view of part of a building
illustrating the major
components.
Fig 2: shows a different aspect of that part of a building.
Fig 3: (as Figs 3a, 3b and 3c) illustrates an example half-height block. Fig
3d shows a
block in cross-section.
125 Fig 4: shows detail of a screwed joint.
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Fig 5: shows detail of a roof tile; lateral view.
Fig 6: shows detail of a roof tile; underneath view.
Fig 7: shows detail of a roof tile, from the downward side.
Fig 8: shows detail of a corner pillar from the groove joint side.
130 Fig 9: shows a triangular wall block having two tongue sides and one
groove side.
Fig 10: shows part of a polyhedral enclosure suitable for use as a dwelling
and made of
tiles such as shown in Fig 9.
Fig 11: shows an isometric view of full panel height components.
Fig 12a and 12b show in elevation and plan a small building constructed from
full panel
135 height components of the types shown in Fig 11.
Fig 12c illustrates the building of Figs 12a and 12b in exploded view.
EXAMPLE 1
Each member of the set of interlockable components for use in the construction
of a
140 building is, according to the invention, comprised of fused
thermoplastics material.
Preferably all parts are manufactured by forming in a single-axis rotational
moulding type
process within moulds. Movements other than simple single-axis rotation may be
used.
The interlockable components provide a set of rectangular or cubic
interlockable wall
blocks rather like bricks or concrete blocks, including a set of half-sized
blocks, a set of
145 corner pillars, and a set of roof panel tiles that are intended for use
in the construction of a
building. Each component conforms to a set of mutually standardised dimensions
at least
with respect to an interlocking or joining portion of each component. It is
also convenient
for those standardised dimensions to conform with local building practices. It
is preferred
that all parts in the range can be joined together at compatible interlocked
joints. They
150 share a common coupling means or joint mechanism, having consistent
dimensions. The
parts in the range include half-size and full-size wall blocks, corner pillars
and door or
window frames, and roof tiles. The parts may be approximately square or may be
elongated such as those shown in Figs 11 and 12 - a, b and c. Note that the
preferred
elongated roof tiles are only partially "cubic" because each tile includes a
dished cross-
155 section. The tiles are intended for side-by-side assembly with the
channel of each dish
directed downwards.
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Each member is made by rotational moulding techniques within moulds and hence
is
comprised of a compatible thermoplastics material. An example fusible plastics
material is
a polyethylene plastics material; for example ICORENE 3840 made by ICO
Polymers, Inc
160 of 6355 Farm Bureau Rd, Allentown, PA 18106, USA. This is a Linear
Medium Density
Polyethylene plastic material. Various resins with different characteristics
may be used,
such as alloys based on the same ethylene with varied co-monomer (hexene,
butene or
octene) raw materials, as is known to those skilled in the art. Such materials
are obtainable
in both solid-setting and foam-setting versions. Preferred moulding
temperatures are
165 between 180 and 280 degrees Celsius. The preferred single-axis
rotational moulding
process has been described in at least PCTNZ2008/000096 (W0/2008/133535), in
which
the present applicant has developed the capabilities of the generic rotational
moulding
process towards making large, flattened or angled sheets of materials
including more than
one layer of plastics. A typical component that has been made in this way has
a hollow or
170 attenuated centre surrounded by a tough, formed skin which had been in
contact with the
walls of the mould and is suitable for internal or external exposure. The
hollow or
attenuated centre may be occupied by thermal insulation which may be comprised
of a
space or be filled with a less dense, foamy yet rigid fused thermoplastics
material made
from a foam-generating type of granules. The space may contain a stored
liquid. Of
175 course, components made by other processes or made from natural
products such as wood
may be incorporated with the rotationally moulded components. Optionally each
tile is
provided with internal insulation means selected from a range including a more
foamy
plastics material, animal or vegetable fibre, or rock or glass wool.
180 WALL COMPONENTS
Figs 1 and 2 show oblique perspective views of part of a building 100, made
from
components created in a rotational moulding machine. The roof 102 is
incomplete, for the
purpose of illustration. There is a channel 106 (fig 2) that provides a
footing for the wall,
which might be formed in concrete or in metal. The walls 101 (and 101A in Fig
2 only)
185 are comprised of an array of interlockable rectangular blocks for
example 110, 110a and
110b as detailed below, which are fitted tightly together during assembly by
tongue 113
and groove 114 joints (details of which are given below) in order to make a
sufficiently
large plane surface wall. Fig 1 shows an opening 103 for a door and another
opening 104
for a window. The door has a lintel comprised of a half-height block ill. That
block has
190 tongues on each side (not shown) . All borders of the door are groove
joints, as shown in
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Figs 1 and 2. A corner pillar 105 ¨ see also fig 8 - is a length of material
fitted with
sufficient tongue joints along one side and groove joints along another side
to
accommodate the joints of several blocks; such as a three-high stack. The
corner pillar
separates wall 101 from another, end wall 101A in a perpendicular plane. Half-
width
195 blocks 115 are used alternately to commence every second course of wall
blocks since the
usual method of construction, like a brick wall, uses overlapping courses of
unit blocks in
order to provide strength. This assembly as described does not include
internal vertical
concrete and iron bar strengthening although holes could be bored through the
hollow or
attenuated centres and parallel to the outer walls, for insertion of steel or
other tensile rods
200 if required by a building code. The wall is seated upon a channel
member 106. A roof 102
is comprised of an array of elongated roof units, as detailed below.
Fig 2 shows the same assembly from a different viewpoint, and identifies wall
101A.
Fig 3 (as Figs 3a, 3b and 3c) provides dimensional details and detailed
orthogonal views
of an example half-width (800 x 400 mm) block. It should be noted that the
dimensions
205 (given here in millimetres) corresponding to a series of standard
blocks presenting an
exposed surface of 800 x 800 mm are by way of example only, and do not in any
way
limit the range of sizes to be provided for by the invention. For instance
dimensions may
be arranged to correspond with the popular 1.2 metre multiples commonly used
by
builders, although the 800 mm size conforms to a typical door width. The
popularity of
210 any one size may in part be dictated by the cost (which may be affected
by a rejection
rate) of manufacturing individual units. The depth or height of the joints is
partially
affected by a desired final assembly strength. Preferably the depth of a
groove is slightly
greater than the height of a tongue.
One preferred style of block is moulded so as to be substantially hollow.
215 Details of a preferred joint arrangement will now be described. Fig 3
includes example
measurements in millimetres for parts 3a and 3b. Fig 3(a) is an edge elevation
view of an
interlockable block version along one edge, wherein 301 is a groove or recess
across the
face extending towards a viewer out through the plane of the drawing.
The dimensions given, by way of example only, in this drawing show: An 800 x
400
220 (usable area) block which has a thinner tongue extending from two
adjacent edges by 70
mm. The thickness of the block is 170 mm; the thickness of the tongue is 148
mm,
leaving 10-11 mm on each "tongue cover" around the 70 mm deep recesses on the
other
two adjoining edges. These tongue dimensions are adequate for the material
from which
the blocks have been constructed ¨ namely a fused thermoplastics material.
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225 When in use each recess would receive a tongue 306 of an adjacent
block. 300 is a groove
along an edge for receiving a tongue 305 from another block. Blocks may be
glued
together although they may also be screwed together for the benefit of easier
installation
and easier disassembly (see later). 302 is one face, perhaps an outer face, of
the block and
304 is the other, perhaps inner face. (In general both faces will be
interchangeable,
230 although it may be preferred that the face intended for exposure to
weathering will have
an included dye or pigment, or other additives for extending the life of the
block when
exposed to weathering. The inventor's moulding process provides a step for
applying a
different thermoplastics mixture to each side.) 303 indicates an indexing
groove, which
receives an inwardly protruding tongue of another block. This is mainly useful
during
235 assembly as a temporary locating means. Fig 3(b) shows a tongue 306
across the face of
the opposite edge elevation of a block and extending towards a viewer out
through the
= plane of the
drawing. =
Fig 3c is a face view of a typical block, showing dimensions, and provision of
tongues
along two adjoining edges. 302 is one face of the block. 305 and 306 are two
tongues.
240 Fig 3d shows a preferred domed surface 307 on the outer (exposed)
surface of a cross-
sectioned wall block. This dome, formed by a dished shape in one face of the
mould,
provides for controlled thermal expansion of the dome when heated, such as by
sunlight.
If the outer surface is left flat then expansion and contraction are not
controlled and the
entire block may bend. Materials thickness may be exaggerated in this section.
Other parts
245 are as previously identified. The internal void may be filled or
partially filled with a
foamed, fused thermoplastics mass.
ROOF (TILE) COMPONENTS
Figs 5, 6 and 7 show a single one of the array of roof tiles 112 that form the
partially
250 completed roof 102 of the building in Fig 1. Fig 5 is a longitudinal
section, showing the
hollow interior 506 of the roof tile which is adapted for side-to-side joining
of an array of
such tiles and fastening as described elsewhere in this section. Each of these
tiles is
intended to span over half a roof from the ridge along the middle and so the
length of the
selected tile determines the size of the room below. However these tiles can
be joined end
255 to end; preferably in a waterproof manner and supported on intermediate
purlins parallel
to the ridge. Fig 7 shows details of a tile coupling arrangement 502, 505 to
be optionally
provided on ends of tiles. Conventional flashing along the ridge of the roof
is useful,
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depending on the environment. Each tile includes a transverse groove 503 (see
Figs 5 and
6) intended to be placed over and attached to the top course of the wall
blocks, near the
260 lower end 505 of the tile 112. The angle of this transverse groove,
which is formed
obliquely into the underside of the tile, partially determines the angle of
the tiles from a
vertical plane ¨ since as shown in Fig 1 this groove sits over the top of the
wall. Fastening
as described elsewhere in this section is intended to be used to fix the tiles
down to the
wall, and at free surface 501, to another array of tiles. The surface facing
the sky, 502, is
265 dished inward, partly for strength and partly to assist in water
collection. (No gutter
arrangement is shown here) The underneath surface shown in fig 6 is dished
outward, up
from the plane of the drawing. The space underneath the tiles may, during
construction,
be packed loosely with a fibre such as animal hair or wool that is held in
place with (for
example) wire netting in order to increase the thermal insulation of the roof.
270 CORNERS
An example of a corner pillar 105 is shown in Figs '1 and 2 at 105, and in
detail in Fig 8.
This example is shown from one side ¨ the "groove" side 114. This drawing
shows the
essentially hollow nature of the corner pillar which structure can be achieved
with
rotational moulding, thereby providing a relatively light pillar. The opening
114 might be
275 strengthened for transport with inserted blocks although, once
assembled, the edges are
held apart from each other by the assembled tongues of the wall tiles (see Fig
3a, 3b or
3c) that are fixed within. The protruding blocks such as 113 are the "tongue"
elements
intended to mate with corresponding grooves of each of three courses of wall
blocks such
as 110 in Fig 1.
280 FASTENERS
The components are held together with one or more of the following preferred
fastening
means:
a. Physical fasteners which traverse the joint, thereby holding the
components to
each other. This option allows deconstruction after the building has been used
in
285 one place, in anticipation of it being needed elsewhere. Fig 4
shows an example of
physical fasteners, namely screws 401 and 402 in a section across a joint
between
blocks 110 and 110a.
b. Physical fasteners may be moulded into the joints, selected from a range
including
mating snap-in lugs and sockets. For disassembly, apertures that allow a tool
to be
290 inserted and then press back the lugs might be provided (not
shown).
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c. Plastics glues selected from a range including solvent glues, two-part
glues such as
epoxies, and glues which become effective when dried,
d. Localised application of heat, thereby locally melting the components on
to each
other, including heat from a heat gun, from an ultrasonic generator, from an
295 included hot wire, or from a reversibly penetrating hot object.
e. Rope, twine, or plant fibre, or rawhide may be used to bind the
structure together.
Holes for passing the bindings through the tiles to be bound together are not
shown. Such holes may be made during assembly.
The physical fasteners as opposed to adhesives allow for the disassembly of a
fabricated
300 building, so that it can be rearranged into another configuration or
taken apart and
transported to another site.
This invention also provides roof tile components as shown in Fig 5, 6 and 7.
EXAMPLE 2
The previous description assumed rectangular components. If the components are
instead
305 triangular blocks, and in particular can be joined together securely
yet allowing the
surface plane of any one triangular block differs from that of adjoining
triangular blocks,
it is easy to fabricate polyhedral dwellings as popularised by the architect
Buckminster
Fuller. They have no distinct roof assemblies. The groove side is placed to
face downward
in order to facilitate drainage. Fig 9 shows a face view of an example
triangular block 900
310 having two tongue edges 901, 902 and one groove edge 903. About half of
the triangular
blocks will require one tongue edge and two groove edges. Fig 10 shows a
portion of a
polyhedral assembly made from triangular blocks 900. The groove aspects of two
of the
blocks can be seen at 1001, which also show the appreciable thickness of each
individual
triangular block.
315 EXAMPLE 3
Example 1 assumed that rectangular components would interlock both
horizontally and
vertically, like bricks or concrete blocks, to form a desired vertical wall
height. The
preferred manufacturing process allows many of the components could instead be
manufactured as full-panel-height pieces each having the same height as the
finished wall.
320 Even as full-height (for instance 2.4 metres in length) the hollow or
foam-centered
components are not too heavy to carry and to place in position. See Fig 11,
which in an
"exploded view" depicts two full height wall panel components (120) aligned to
interlock
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with the corner column (105). A finishing full height component (130) is
provided for use
where a narrower wall section is desired, for example as a frame for a door or
a window.
325
Immediately after extrusion each component may be laid on to a moving flat
conveyor
belt in order that it can set solid without distortion.
As an illustrative example, a small worker's accommodation built from such
full panel
height components is shown in Fig 12a (elevation view), 12b (plan view), and
12c as
exploded view of components 600. Fig 12c includes: floor panels 122, cutout
wall panels
330 121 for use in framing a window, a window lintel 123, a door lintel
111, and two door
frame components 130.
METHOD
The principles of this component manufacturing method have been described
previously
by the inventor, but some modifications, and the shapes of the moulds are
novel. An
335 example method for manufacture of interlockable components according to
the invention
includes the steps of:
a. making an openable and releasable mould which can conduct heat into the
interior
for each distinct shape of component, and which maintains access for the
introduction of granules into the interior of the mould when being rotated
during
340 use;
b. heating an oven to a working temperature ¨ which is related to a softening
temperature for the selected thermoplastic material, typically between 180 and
280
degrees Celsius;
c. placing each mould in the oven and heating it to a selected temperature;
345 d.
introducing a first granular non-foaming thermoplastics material while
rotating the
mould for a time so that all parts of the mould become internally coated with
fused
thermoplastics material;
e. optionally then introducing a foam-generating inner thermoplastics material
while
continuing to rotate the mould so that an inner void within the mould become
350 internally coated with the thermoplastics material;
f. after a time removing each mould and allowing it to cool;
g. opening the mould;
h. and optionally trimming at least the mating joint surfaces of each
component once
moulded and cooled using a cutting tool ¨ such as a saw or an end mill along
with
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355 a holding vice or jig - so that its dimensions become fully
controlled regardless of
shrinkage or sagging.
Many of the components described here could not be made in a two-axis, closed
mould.
The temperature is best set by experience. Too low a temperature will lead to
extended
fusion times, and too high a temperature causes decomposition of the plastic.
The
360 readings are dependent on transducer placement. Of course the
temperature also depends
on the selected plastics material.
The variation at the step (e) provides each component with improved thermal
insulation
and extra mechanical strength without much increase in weight.
Another variation at the step (d) includes (dl) placing a first variation of a
non-foaming
365 granular mixture on a first face of a tile or the like, fusing it in
place while agitating or
only partially rotating the mould, and then (step d2) rotating the mould
through 180
degrees, introducing a second non-foaming granular mixture into the mould, and
then
commencing single-axis rotation of the mould, so that the second mixture tends
to coat
the remainder of the inner surface of the mould. That modification causes the
outer
370 surface of the mould to have a different composition, such as one
including a pigment (for
example titanium dioxide for white, iron oxide for red, or carbon for black.
It will be appreciated that these components are easily stacked for transport,
such as on
pallets or in containers. The blocks might be made by injection moulding or
other
methods, rather than rotational moulding.
375 Some of the components, especially the elongated ones shown in Figs 11
and 12 might be
made economically by plastics extrusion techniques. In this variation, an
extruded box
section including the groove joint along two adjacent edges and the tongue
joint along one
edge is made. Post-processing includes the steps of cutting out squares at for
example 800
mm spacings along the box section, inserting and gluing into place a
separately made
380 tongue section so that the completed block bears a tongue joint
component along two
adjacent edges.
VARIATIONS
Doors and windows themselves have not been described, but may be made from
plastics
or wood or glass, and may be replaced by simple curtains in some
circumstances.
385 The channel 106 that provides a footing for the wall may be made from a
metal
Exposed surfaces may be painted, for example with white paint for thermal
resistance.
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In order to reduce the total consumption of plastics, a stone aggregate may be
mixed with
the thermoplastics material for moulding at least some of the components.
Optionally at least some of the components are comprised of a material based
on concrete
390 rather than a thermoplastics material.
The blocks might be made by injection moulding rather than rotational
moulding.
The blocks might be made by extruding a box section including the groove joint
along
two adjacent edges and the tongue joint along one edge, and after cutting
squares at for
example 800 mm spacings along the box section, inserting and gluing into place
a
395 separate tongue section so that the completed block bears a tongue
joint component along
two adjacent edges.
The plane surfaces of the wall blocks previously described in this section may
be replaced
by curved surfaces; preferably curved in more than one plane at one time, so
that
increased strength per unit of weight is provided. Apart from the domed walls
previously
400 described in this section, one version of this would appear like
corrugations with a pitch
of perhaps 50 mm.
RESULTS AND ADVANTAGES
This invention provides prefabricated components for buildings, so that a
building can be
carried to a site as individual or aggregated components as dictated by the
transport
405 facilities available, then erected at the site. Optionally, the parts
for the building are
temporarily attached, but are not fused together permanently, so that the
building can be
taken down when no longer required, and used again elsewhere.
The inventor believes that these buildings may be of particular use as housing
for disaster
relief or for providing shelter to homeless persons.
410 Finally it will be understood that the scope of this invention as
described and/or illustrated
herein is not limited to the specified embodiments.
13
