Block for use in automated building construction

Patent metadata

Field	Value
Publication number	US-12065826-B2
Application number	US-202318109574-A
Country	US
Kind code	B2
Filing date	Feb 14, 2023
Priority date	Oct 4, 2017
Publication date	Aug 20, 2024
Grant date	Aug 20, 2024

Abstract

The present disclosure relates to the building industry and in particular to a block for use in automated building construction. In one aspect, the block comprises a generally cuboid body having a top and a base, a length extending between a pair of opposed ends, and a width extending between a pair of opposed sides; the body including a plurality of hollow cores extending from said top to said base, and arranged in a row between said opposed ends; wherein each core has a rectilinear cross-sectional shape; and wherein the thickness of the block between each pair of adjacent cores is at least double the thickness of the block on all other sides of each core, so that the block is divisible into a plurality of substantially identical block portions, each portion including four walls of substantially uniform wall thickness about its core.

First claim

The invention claimed is:

1. A block for use in automated building construction, the block comprising:
a cuboid body having:
a) a top and a base;
b) a length extending between a pair of opposed ends;
c) a width extending between a pair of opposed sides;
d) a plurality of hollow cores extending from said top to said base, and arranged in a row between said opposed ends; wherein each core has a rectilinear cross-sectional shape, wherein a first thickness is formed between each pair of adjacent cores and a second thickness is formed on all other sides of each core; and

wherein the first thickness of the block between each pair of adjacent cores is at least double the second thickness of the block on all other sides of each core, so that the block is divisible into a plurality of substantially identical block portions of rectilinear cross-sectional shape, each portion having a respective core, each portion including four walls of a substantially uniform wall thickness about the respective core, and wherein the walls extending about the cores include a plurality of secondary cores extending from said top to said base, the secondary cores separated by a plurality of webs,
wherein the block includes at least one tongue located at a first of the opposed ends, and at least one groove located at a second of the opposed ends, each groove being configured to at least partially accommodate a tongue of an adjacent block, wherein each tongue and each groove extend vertically from the top to the base of the block.

2. The block according to claim 1 , wherein the block includes four hollow cores, so as to be divisible into four substantially identical block portions.

3. The block according to claim 1 , wherein the cores comprise at least one of:
a) a square cross-sectional shape; and,
b) a rectangular cross-sectional shape.

4. The block according to claim 1 , wherein each hollow core is spaced evenly from each of the opposed sides, and the hollow cores adjacent each end are spaced evenly therefrom.

5. The block according to claim 1 , further including at least one rectangular recess for accommodating a rectangular-section tie plate, wherein the at least one rectangular recess is located on a top face of the block and extends one or more of:
i) transversely between a respective hollow core and a side of the block;
ii) longitudinally between a respective hollow core and an end of the block; and,
iii) longitudinally between respective hollow cores of the block.

6. The block according to claim 1 , wherein a respective said block portion is divided from the block by a cut made at a midpoint between adjacent cores.

7. The block according to claim 1 , wherein the block is for use in constructing an external wall, the block having:
a) a length of approximately 490 mm;
b) a width of approximately 240 mm;
c) a height of approximately 230 mm; and,
d) a dry mass of approximately 17 to 22 kg.

8. The block according to claim 1 , wherein the block is for use in constructing an internal wall, the block having:
a) a length of approximately 490 mm;
b) a width of approximately 115 mm;
c) a height of approximately 230 mm; and
d) a dry mass of approximately 10 to 14 kg.

9. The block according to claim 1 , wherein the block is manufactured from a mixture including at least:
a) water;
b) cement; and,
c) a lightweight expanded aggregate being one of:
i) an expanded clay aggregate;
ii) an expanded slate aggregate;
iii) an expanded shale aggregate; and
iv) an expanded glass aggregate.

10. The block according to claim 9 , wherein the mixture further includes one or more of:
a) a plasticizer; and
b) a fine aggregate.

11. The block according to claim 9 , wherein the mixture includes: lightweight expanded aggregate is a lightweight expanded clay aggregate (LECA) having particles of diameter at least one of 0 mm-1 mm, 1 mm-2 mm, 2 mm-3 mm, 3-4 mm, 4 mm-5 mm, 5 mm-6 mm, 7 mm-8 mm, 8 mm-9 mm and 9 mm-10 mm.

12. A wall assembly including a plurality of said blocks according to claim 1 laid in a plurality of courses, and an adhesive applied between each course of blocks and a successive course to bond these.

13. The wall assembly according to claim 12 , further including one or more block portions divided from a block or a remainder thereof by a cut made at a midpoint between adjacent cores.

14. The wall assembly according to claim 12 , wherein cores of blocks in the wall assembly are used as conduits for carrying services for a building.

15. The wall assembly according to claim 12 , further including a render applied to at least external surfaces thereof.

16. The wall assembly according to claim 15 , wherein the render is an acrylic non-porous render to seal a wall from moisture ingress.

17. The wall assembly according to claim 12 , wherein the adhesive is machine applied to the base of a block before being laid onto a lower course.

18. The wall assembly according to claim 17 , wherein at least two parallel beads of adhesive are applied onto the base of a block along a lengthwise extent thereof.

19. The wall assembly according to claim 17 , wherein the adhesive is further applied onto one or more end faces of a block so as to form a perp joint with an adjacent block in a course.

20. The wall assembly according to claim 12 , wherein the wall assembly is assembled using a plurality of first blocks having a first width and a plurality of second blocks having a second width twice that of said first width plus the thickness of the spacing between the blocks.

21. The wall assembly according to claim 20 , wherein the first blocks are internal blocks that are used substantially in the construction of internal walls and the second blocks are external blocks that are used substantially in the construction of external walls.

22. The wall assembly according to claim 21 , wherein internal walls are tied into external walls by at least one of:
a) inserting internal blocks between adjacent external blocks for at least alternating courses of blocks so that ends of the internal blocks lay flush with an outer face of an external wall;
b) forming a cut-out in an inner face of one or more external blocks and locating an internal block into the cut-out to thereby interlock the blocks; and
c) by tie clips used in one or more of the courses.

23. The wall assembly according to claim 21 , wherein internal walls are tied into external walls so that overlapping hollow cores of respective internal and external blocks are substantially aligned.

Assignees

• Fastbrick Ip Pty Ltd

Inventors

• Pivac Mark Joseph

Classifications

• E04C1/397

  serving for locating conduits (E04C1/392 takes precedence) · CPC title

• E04C1/00

  Building elements of block or other shape for the construction of parts of buildings (of relatively thin form E04C2/00; structural elongated elements designed for load-supporting E04C3/00, e.g. columns or pillars E04C3/30; manufacture or material of building bricks, stones, or the like B28, C03, C04; paving elements E01C; general building constructions E04B, e.g. walls E04B2/00, floors E04B5/00, roofs E04B7/00, ceilings E04B9/00; {roof coverings E04D; coverings for walls or ceilings E04F13/00; floorings E04F15/00;} structural elements specially designed for built-in conduit shafts E04F17/00; {elements for buildings for particular purposes E04H7/00}; special elements for building ovens or furnaces F24B, F27D) · CPC title

• E04B2002/0289

  Building elements with holes filled with insulating material · CPC title

• E04B2002/0273

  Adhesive layers other than mortar between building elements · CPC title

• E04B2002/026

  Splittable building elements · CPC title