Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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Building block
The present invention relates to a building block for a building construction,
where a number of building blocks put together form a wall or the like,
comprising a rectangular, precast building block, as the building block
comprises an outer surface layer on each side and an intermediate, insulating
middle layer of corresponding material with a lower density than the surface
layers, and that the building block comprises at least one vertical channel
arranged to receive at least one locking plug and/or reinforced concrete.
The present invention is a new product for construction of insulated outer
walls,
primarily for dwelling houses, but can, of course, also be used for industrial
buildings and other building constructions. The product is specifically
developed to simplify house building and reduce costs, but at the same time is
qualitatively as good as any product on the market today.
There are a number of building blocks on the market today. These can be
divided into some main categories: Concrete blocks, lightweight blocks,
insulation blocks and hybrids. Pure concrete blocks are partially used as
hollow
stacking blocks. These can be stacked without mortar between them, thereafter
reinforced concrete is filled into the hollow spaces. Walls built in this way
are
inaccurate in their form and are non-insulated. They are preferably used as
supporting walls.
Lightweight blocks are laid in a traditional way with mortar, and are very
popular
as foundation wall material for dwelling houses and as walls in frame con-
structions. LecaTM is a typical product in this category. Such blocks are also
made as hybrids. LecaTM has such a product where a disc structure is made
with the usual material on each parallel wall surface and with a core of
polyurethane foam. This gives a 300 millimetre thick wall that is completely
insulated with regard to the strictest Norwegian regulations. Such a solution
is
not used much, as much effort is required for the insulation in the mortar
layers.
Pure insulation blocks are a product where one casts EPS blocks in a factory.
These can be stacked to a certain height and thereafter be filled with
reinforced
concrete. Thereafter it is necessary to polish both sides to achieve a firm
wall.
These are also used relatively rarely. All these block types have their advan-
tages and disadvantages. The aim of the invention is to develop a product that
combines the best in all the other products.
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Primarily, there are four main aims behind the product which has been
developed: simple and easy to lay, extremely even surfaces after laying, high
insulation capacity and fire safe. It is a further aim to add secondary
characteristics. The material shall also have good characteristics for
insertion of
screws, something that optimises for both nailing and screwing.
The wall will be horizontally open to diffusion, but the biocks can however be
sealed with a silicone spray such that they are diffusion tight vertically. No
other
product in today's market seems to have this combination of characteristics.
It is a further long term aim to be able to build walls with the help of
robots. The
starting point will be a construction programme for all deliveries of the
system
according to the invention. The construction programme will be developed in
parallel with the detailed development of the product and production. Here,
architect drawings will be converted to construction drawings, material lists
and
delivery documentation.
From prior art, attention shall be given to Fl 25045, US 5,002,620, DE 32
36 187 Al and Norwegian Application NO 2000 5692. All the documents
concern building blocks for a building construction where a number of building
blocks are intended to be put together to form a wall or the like and where
the
building block is a rectangular, precast block.
Short description of the invention
The building elements according to the invention preferably comprise EPS balls
with cement as a binding agent. This is a well-known product which is produced
in several locations in the world. The present product has some additional
materials that offer extra toughness in casting and in use. These are aiso
known materials. What is special about the present invention lies in the
shape,
composition and production of the blocks.
The material that is used has different densities in the cross-section of the
blocks. The building element according to the invention can have two surface
layers, each one with a thickness of, for example, 20 millimetres, which
preferably has the highest density. This provides the necessary strength
requirements for a completed wall. A middle layer can have a low density. This
provides the necessary insulating characteristic. Both layers can be optimised
further in the subsequent development of the product. No information is
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available about others that use different densities of this material in the
same
product. The dimensions of the block can, for example, be 300 x 300 x 599
millimetres. The length can possibly be somewhat adjusted later, where all the
surfaces are plane. Furthermore, vertical openings are provided in the blocks,
for example, a circular opening of 120 millimetres diameter in the centre and
two corresponding semi-circular openings at each end. This provides circular,
vertical hollow spaces of 300 millimetres vertical distance when the blocks
are
laid in a course. The internal surfaces of the blocks can be sealed during
production with silicone spray or the like. This is to protect the insulation
layer
against careless handling and against ingress of water during laying when it
is
raining. This will also ensure the guiding holes against unwanted wear during
laying. In addition this will give diffusion tightness in two directions of
the wall.
The external surfaces will initially not be sprayed so that the blocks can be
open to diffusion across the wall.
During building, every other hole can be plugged with a locking plug, of a
material that corresponds to the insulating material. This give a stable wall
in
the initial phases of construction. At the same time the blocks are locked in
a
completely accurate position in relation to the other blocks. This gives an
approximately smooth wall surface. Every other hole is preferably filled with
reinforced concrete to give the wall large load bearing strength. The function
of
the locking plug must be seen in connection with the production method for the
blocks that will give the blocks the exact same dimensions, straight surfaces
and right angles. The blocks are therefore locked exactly in relation to each
other and the completed wall will be of a very high quality. The function of
the
locking plug, together with the possibilities of good tolerance in its method
of
production, are one of the most central parts of the new development.
All material thicknesses are initially of standard dimensions, but can be
adjusted according to the wishes of the customer.
The plugs are in the main comprised of the same materials as the blocks. The
plugs can be somewhat pointed at one end and thereafter get a special surface
treatment to increase the thickness and to withstand the mechanical strain
during laying. In production of the blocks, excess material can be
recirculated.
Besides, there can be an opportunity to use recirculated isopor from other
sources optimally, to a smaller and larger extent.
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The above mentioned aims are achieved with a building block which is
characterised by the characteristics in the independent claim 1, in that the
building block is manufactured from EPS balls with cement as a binding agent
and that said vertical channel(s) is formed as a through-going, circular
opening
between the end surfaces of the block and/or a semi-circular groove on at
least
one end of the block, whereby a circular opening is formed between two
adjoining building blocks, as a number of said vertical channels in the
building
block are arranged to receive respective locking plugs formed at least
partially
from the same material as the building blocks.
Preferred alternative embodiments are characterised by the dependent claims
2-8. The through-going, circular opening between the end surfaces of the block
is preferably arranged centrally in the block and the block comprises a semi-
circular grove on each end of the block.
One or more of the internal surfaces of the building block can comprise a
sealant such as silicone.
A top block can comprise a horizontal, mainly U-shaped duct that runs in the
longitudinal direction in an upper part of the building block. A corner block
can
comprise a through-going opening and only one semi-circular groove at one
end, and the other end can comprise an outer surface layer.
A specific embodiment of the building block can be formed with the dimensions
300 mm x 300 mm x 599 mm, where the surface layers are formed with a thick-
ness of 20 mm and the channels are formed with a diameter corresponding to
120 mm.
In the main, the vertical channels run through the building construction
centrally
in the building blocks and between the building blocks, and a selection of
vertical channels can be filled with reinforced concrete, preferably every
other
channel.
A locking plug is preferably formed in a circular-cylindrical shape or in a
semi
circular-cylindrical shape.
The invention shall now be described in more detail with reference to the
enclosed figures, in which:
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Figure 1 shows a perspective drawing of a general building block
according to the invention.
Figure 2 shows a perspective drawing of a top block according to the
invention.
5 Figure 3 shows a perspective drawing of two end blocks put together to
form a corner according to the invention.
Figure 4 shows a perspective drawing of parts of a building construction
according to the invention.
Figure 5 shows correspondingly a perspective drawing of parts of a
building construction according to the invention.
Figure 6 shows a transparent perspective drawing of parts of a building
construction according to the invention.
Figure 7 shows a perspective drawing of parts of a building construction
according to the invention.
Figure 8 shows correspondingly a perspective drawing of parts of a
building construction according to the invention.
As mentioned, the invention relates to a building block 10 for use in a
building
construction 50, where a number of building blocks 10 placed together form,
for
example, a wall. The building block 10 according to the invention is in the
main
formed as a rectangular, completed building block and which comprises an
outer surface layer 12, 14 on each side surface and an intermediate,
insulating
middle layer 16 of a lower density than the surface layers. Furthermore, the
building block 10 comprises vertical, through-going channels 18, 20 arranged
to
receive at least one locking plug 60, 62 or reinforced concrete. Said channels
are shaped as a through-going circular opening 18, in the main centrally in
the
block, and a semi circular groove 20 at each end of the block, whereby a
circular opening 52 is provided between two adjoining building blocks 10.
Figure 1 shows an example of a building block 10 according to the invention.
The building block according to the embodiment example is preferably formed
with dimensions 300 mm x 300 mm x 599 mm, where the surface layers 12, 14
are made with a thickness of 20 mm and the through-going, central channel 18
is formed with a diameter of 120 mm. The dimensions of the side channels 20
are consequently half of the diameter of the middle channel 18, so that when
two buiiding blocks 10 are placed together, the same diameter is created in
all
channels. The dimensions of the building block are consequently not limited to
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the above mentioned dimensions, but can be produced in the dimensions that
are desired or practical.
The building block 10 is cast in its own production process, and is treated so
that it has the desired shape and size. The building block 10 is preferably
manufactured from EPS balls with cement as binding agent. EPS stands for
expanded polystyrene, and is a petroleum product. EPS does not contain
KFK/HKFK. When using EPS as building insulation material, one saves a lot of
energy, and thus protects the environment. EPS does not dissolve in water or
air and therefore does not pollute the environment. Fungi and bacteria can not
grow on EPS. If one wishes a greater pressure strength or moisture resistance,
XPS, or any other corresponding material, for example can be used completely
or partially in place of EPS.
One or more of the internal surfaces of the building block 10, i.e. the
channels
and/or surfaces of opposite building blocks that face each other, can be
comprised of a sealant such as silicone. The aim of this is to protect the
insulating layer against careless handling and against ingress of water when
laying when it is raining. Furthermore, the channels are also protected
against
unwanted wear during laying. In addition, this provides diffusion tightness in
two
directions of the wall. Initially, the external surfaces will not be sprayed
so that
the blocks can be open to diffusion across the wall, but a sealant can, of
course, be applied to all surfaces if appropriate.
Figure 2 shows an example of a top block 30. The top block 30 is in the main
manufactured and formed in the same way as given above, but comprises in
addition a groove or duct 32 that runs in the whole or parts of the upper
section
of the block. The groove or duct 32 is formed so that it can be filled with
armouring and concrete, or the like, and can function as a cast concrete
girder.
The depth of the groove or duct is adapted to the desired amount of armouring
72 and fill material 74.
Figure 3 shows two corner blocks 40 which are put together. The corner block
is in the main manufactured and formed in the same way as described
35 above. However, the corner block 40 will comprise a through-going opening
18
and only one semi circular groove 20 at one end, and the other end 42 can
comprise an outer surface layer corresponding to that of the side surfaces of
the building block. Alternatively, the corner block can comprise a tapered end
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edge, or the corner block can be formed in an L-shape. Furthermore, the
corner block can be made to be shorter than said building blocks 10, and the
through-going opening 18 is no longer arranged centrally in the block, but
arranged so that the opening runs through the over lying and/or under lying
corner blocks centrally in the corner of the building construction. The top
corner
blocks can be formed with a groove or duct 32 corresponding to that described
for the top block.
The figures 4-8 show different examples of the building up of parts of the
building construction 50. The preparation of the foundation is carried out in
a
known way and will not be described further. It can be seen that building
blocks
are placed adjoining each other so that a through-going opening 52 is provided
between the channels 20 at the end of the building block. A locking plug is
thereafter placed in the openings 52 and 18. The locking plugs 60 are
preferably formed with a circular-cylindrical shape with the same diameter as
the openings. However, a semi-circular cylindrical locking plug 62 can be used
in the corner of the building construction, as shown in the figures 4 and 5.
The
length of the locking plugs can be corresponding to the height of the building
blocks, or alternatively longer so that they run vertically through several or
all
the building blocks. Every other opening 18, 52 is preferably filled with
concrete
70. Openings for doors and windows can be cut out after the wall has been
completed, or such openings can be adapted during the fitting of the building
elements.
The locking plugs are, as mentioned, preferably manufactured from the same
material as the building block, and then especially of the same material as
the
middle layer of the building block. However, it can be necessary to harden the
locking plugs by the addition of an outer surface layer, such as cement.
Furthermore, it can be relevant as an alternative to manufacture the locking
plugs from a different material than the building blocks if this is required
or
appropriate.
