AU2011200110B2

AU2011200110B2 - Building block

Info

Publication number: AU2011200110B2
Application number: AU2011200110A
Authority: AU
Inventors: Enzo Palma
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-01-13
Filing date: 2011-01-12
Publication date: 2017-01-12
Anticipated expiration: 2031-01-12
Also published as: AU2011200110A1

Abstract

The present invention provides a building block 10 comprising an outer layer 30 comprising at least one wall panel 31, 32, 33, an inner layer 20 5 comprising at least one pipe member 21, whereby the inner layer 20 is in direct contact with the outer layer 30 and at least one connector member 60 for connecting one or more adjacent building blocks 10 together. :::000 0 0CC- CO/, OOCOODDocll 20 Figure 1 2849290vl

Description

2011-0 Ί-12 19:19 PRIVATE 0394088294 » P 4/23 2011200110 12 Jan 2011

Regul. P/00/011 lation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT

Invention Title: "BUILDING BLOCK"

The following statement is a full description of this invention, including the best method of performing it known to me: COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 2011-01-12 19:19 PRIVATE 0394088294 » P 5/23 2011200110 12 Jan 2011

COMPLETE SPECIFICATION FOR A STANDARD PATENT in the name of

Enzo Palma entitled "BUILDING BLOCK"

Filed by;

FISHER ADAMS KELLY Patent and Trade Marie Attorneys Level 29 12 Creek Street BRISBANE QLD 4000 AUSTRALIA COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 2011-01-12 19:19 PRIVATE 0394088294 » P 6/23 2011200110 12 Jan 2011 1

TITLE

BUILDING BLOCK FIELD OF THE INVENTION 5 The invention relates to building materials and Structural components, and in particular, to a building block which provides a simple and effective building material that is easy to use for the constrtuction of building structures.

10 BACKGROUND TO THE INVENTION

There are various types of building materials used to make structures such as houses and offices, encompassing everything fiom mud, metal, plastic and grass, to more commonly used materials such as cement and bricks. Generally, the choice of material will depend on the durability, IS aesthetics, ease of construction, and the cost of the material. In much of the western world, houses and related structures are commonly nr ade from bricks, timber, and/or cement.

Brick buildings are generally provided in double brick or brick veneer forms. Double brick involves the walls of a house being built with two layers 20 of brick masonry 'separated by a narrow air cavity. The internal walls are often made of plaster. However, it is the bricks that provide the building's structural support. Brick veneer walls consist of a single external layer of brickwork supported by a lined stud frame inside, which is usualty finished with plaster on the internal wall. COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 2011-0 Ί-12 19:20 PRIVATE 0394088294 » P 7/23 2011200110 12 Jan 2011 proofing, le brick k veneer r houses hereto re mp and : appeal of

Double brick buildings have excellent insulation and sound together with great structural strength. For these reasons, doub homes remain the "preferred" option by buyers as opposed to brie homes. The disadvantage with both double brick and brick venee 5 is that they require large amounts of skilled labour, and are expensive to build. Brick houses are also susceptible to rising water mould which, over time, reduces the integrity and aesthetic the house. In recent times, pre-fabricated materials and building u 10 been developed in order to decrease building construction time, houses can be made using concrete bricks or prefabricated wails, Walls can be prefabricated off-site and erected on-site usinc or alternatively, framework can be constructed and cement pouri with the framework being removed once the cement has cured. 15 both these methods are labour intensive and require skilled tradesi A more recently developed building material is EPS fban|i which are foam blocks into which concrete is poured to create structure. However, the disadvantage with this material is that it used to make single walled buildings which must be cut into 20 installation of wiring and building services. Furthermore, an extra coating needs to be applied to the foam in order to strengthen the Walls. d ai nits have Concrete concrete a crane, into it, However, men. boards, desired only be for the exterior '<>d ths can COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 20 Ί1-01-12 19:20 PRIVATE 0394088294 » P 8/23 2011200110 12 Jan 2011

OBJECTS OF THE INVENTION

It is a preferred object of the invention to provide a build ng block that addresses or ameliorates one or more of the aforementioned problems of the prior art or provides a commercial alternative.

It is a preferred object of the invention to provide a build ng block which is adaptable to provide different configurations for domestic and commercial dwellings.

It is a further preferred object of the invention to provide ^ building block which is easy to use and cost-effective. 10

SUMMARY OF THE INVENTION

According to one aspect, the present invention resides in ^ building block comprising: an outer later comprising at least one wall panel; 15 an inner layer comprising at least one pipe member, whereby the inner layer is in direct contact with the outer layer; and adjacent material s roving at least one connector member for connecting one or more building blocks together.

Preferably, the building block is made of a composite fibre 20 including, but not limited to, a mixture of cardboard and continuolu glass, lightweight sand, resin, fibreglass or the like. dw. an inner

Preferably, the pipe member is cylindrical in shape and holl

Preferably, the outer layer comprises an outer wall panel, wall panel and two side wall panels. COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 2011200110 12 Jan 2011 2011-0 Ί-12 19:20 PRIVATE 0394088294 » P 9/23

Suitably, the outer wall panel, the inner wall panel and the two side wall panels are positioned so that the outer layer forms a rectangu ar shape for the building block.

Preferably, the height of the outer wall panel, the inner Wall panel and the two side wall panels of the outer layer is higher than that of the at least one pipe member of the inner layer such that the inner layer will completely covered to provide the appearance of a solid building block.

Preferably, the outer layer has at least one coating layer which is applied to its surface. 10 Suitably, a first coating layer is a gelcoat material which is Applied to the outer wall of the outer layer of the building block.

Suitably, a second coating layer is a plasterboard/pla rterboard paper which is applied to the inner wall of the outer layer of the building block. 15 Preferably, the building block further comprises at least on4 aperture which is adapted to receive the connector member therethrough.

Preferably, the at least one aperture is provided on the side wall panel($) of the building block, extending dirough the outer Ibyer and partially through a first pipe member of the inner layer of the buildii tg block. 20 Suitably, the connector member is in the form of a rod-like member for connecting adjacent rows of building blocks in a horizontal and/or vertical direction

Preferably, the at least one pipe member and/or the outer layer is produced via a filament winding process. COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 2011200110 12 Jan 2011 15 20 20ΊΊ-0Ί-Ί2 19:21 PRIVATE 0394088294 » P 10/23

Preferably, the filament winding process involves a single layer of composite fibre being immersed in a resin bath, where the layer s coated with low or medium molecular weight reactants to provide an impregnated layer of composite fibre. 5 Preferably, the resin is an orthophthalic neopentyglycol unpatu rated polyester resin.

Preferably, the at least one pipe member is formed by wjnding an impregnated layer of composite fibre around a mandrel (mold pore) in a controlled pattern to form the shape of the at least one pipe mednber and 10 cured.

Further aspects and features of the present invention wit become apparent from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

By way of example only, preferred embodiments of the invention will be described more fully hereinafter with reference to the accompanying drawing, wherein:

Figure 1 is a plan view of two rows of a pair of intercjonnected building blocks.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In this preferred embodiment, the invention provides a builping block which provides a simple and effective building material that is earty to use, for the construction of building structures. The building block of the COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 2011200110 12 Jan 2011 icn iyided an 10 is nhixture of fibreglass can also building ng block leriber 21. temative preferred meter of that the uired to ss of the required will also the pipe kick req 2011-0 Ί-12 19:21 PRIVATE 0394088294 » P 11/23 6 invention is particularly suited for building residential dwellings and commercial properties and other similar scale buildings. However, it is envisaged that the invention may also be used for the constructs n of any other suitable structure. 5 The building block 10, as illustrated in Figure 1, has pro inner layer 20 and an outer layer 30. Preferably, the building bl made of a composite fibre material Including, but not limited to, a cardboard and continuous roving glass, lightweight sand, resin, or the like. It will be acknowledged that any other suitable material 10 be employed. Preferably, the material(s) selected will provide the block 10 with the requisite strength whilst ensuring that the build i 10 remains lightweight so that it is easy to transport and work with.

The inner layer 20 comprises at least one pipe mi Preferably, the pipe member(s) 21 are cylindrical in shape. In a 15 embodiments, any other suitable shape can be adopted. In a embodiment of the invention, the pipe member 21 will have a didu 125 millimetres and a height of 2.7 meters. It will be acknowledge^ shape and dimensions of the pipe member 21 may be varied as provide different building blocks 10. It is envisaged that the thickndi 20 pipe member 21 may also be varied to depending on the strength by the building block 10. The number of pipe members 21 utilised be dependent on the size of the building block 10 and the size o member 21 itself. Preferably, the pipe member 21 is vertically drientated COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 2011200110 12 Jan 2011 2011-01-12 19:22 PRIVATE 0394088294 » P 12/23 within the building block 10 and positioned adjacent to one another along the entire length of the building block 10.

Preferably, the pipe members 21 are produced via a filament winding process (not illustrated). According to some embodiments, the 5 filament winding process of the invention involves a single layer of composite fibre being immersed in a resin bath, where the layer s coated with low or medium molecular weight reactants. The resin, preferably an orthophthalic neopentyglycol unsaturated polyester resin, ccintent is preferably lower than normal in order to minimise the weight of the pipe 10 member 21. The impregnated fibre layer is then wound around a mandrel (mold core) in a controlled pattern to form the shape of the pipe member 21. Preferably, the fibre layer is preferably wound at an angle of ninety degrees in order to increase the hoop strength of the fibre. After winding the resin is then cured, typically using heat. The mold core is then removed 15 to create a central aperture (not illustrated) within the pipe me mber 21 which extends along the entire length of the pipe member 21. In alternative embodiments, the pipe members 21 can also be made via e ny other suitable method or process, using the same or different materials.

The outer layer 30 comprises at least one wall panel. According to 20 some embodiments, the outer layer 30 comprises an inner wall >anel 31, an outer wall panel 32 and two side wall panels 33. Preferably, the outer layer 30 can be produced via the same filament winding process used to create the pipe members 21. In alternative embodiments, any other suitable method or process can be utilised. It is further envisaged that the COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 2011200110 12 Jan 2011 the wall the pipe 20ΊΊ-01-12 19:22 PRIVATE 0394088294 » P 13/23 8 material composition of the outer layer 30 can be the same as, Of different to, tiie material composition of the inner layer 20 of the building block 10. Preferably, the outer layer 30 of the building block 10 is positioned in direct abutment with the inner layer 20 of the building block 10 so that the inner wall panel 31 of the outer layer 30 is in contact with the outer surface of the pipe members 21 of the inner layer 20,

The wall panels 31, 32, 33 are positioned so that the outeif layer 30 provides a rectangular shape for the building block 10. It will be acknowledged that the building block 10 can come in various s tapes as 10 required by the building structure or application. The height of panels 31, 32, 33 of the outer layer 30 is higher than that of members 21 of the inner layer 20 such that the inner layer 20 will completely covered to provide the appearance of a solid building block 10. The size and dimensions of the wall panels 31, 32, 33 can l>e varied IS depending on the number of pipe members 21 which must be covered and/or size of the building block to be constructed. In a further embodiment of the invention, the building block 10 can also be adapted to accommodate windows and doors within the building, or it may be adapted to be (formed in a shape not commonly used in standard buildings, such as a curved shape 20 for a round building.

According to some embodiments, the building block 10 hale at least one coating layer applied to the surface of the outer layer 30 of ths building block 10. Preferably, a first coating layer 41 is applied to the surftice of the outer wall panel 32 of the building block 10 so that the building block 10 will COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 9 2011200110 21 Sep 2016 members 21 of the inner layer 20 such that the inner layer 20 will be completely covered to provide the appearance of a solid building block 10. The size and dimensions of the wall panels 31, 32, 33 can be varied depending on the number of pipe members 21 which must be covered 5 and/or size of the building block to be constructed. In a further embodiment of the invention, the building block 10 can also be adapted to accommodate windows and doors within the building, or it may be adapted to be formed in a shape not commonly used in standard buildings, such as a curved shape for a round building. 10 According to some embodiments, the building block 10 has at least one coating layer applied to the surface of the outer layer 30 of the building block 10. Preferably, a first coating layer 41 is applied to the surface of the outer wall panel 32 of the building block 10 so that the building block 10 will be adapted to withstand weathering and be easily cleaned. Preferably, the 15 first coating layer 41 is a gelcoat material. However, any other suitable material can also be adopted. The first coating layer 41 can be pre-applied to the block during production of the block or applied at a later stage prior to, or following, installation of the building block 10. Gelcoat material provides a high quality finish on the external surface of the fibre-reinforced 20 composite building block 10. The most common gelcoat materials have an epoxy or unsaturated polyester resin composition. In an alternate embodiment of the invention, it is envisaged that an additional layer (not illustrated) can be applied to the exterior surface following production of the 2849292v1 10 2011200110 21 Sep 2016 building block 10 using a material which is adapted to provide a decorative finish for the building/structure such as paint or any other suitable material. Preferably, the additional layer could be coloured to suit the furnishings and/or decor/style of the dwelling, building or structure. It is envisaged that 5 the external finish can be in situ or part of the building. A second coating layer 42 is applied to the surface of the inner layer 20 of the building block 10 facing the inside of the dwelling/building. Preferably, the second coating layer 42 is a plasterboard or other similar material, which can receive a further decorating coating such as paint or 10 the like. The second coating layer 42 can be pre-applied to the block during production of the block or applied at a later stage prior to, or following, installation of the building block 10. In an alternative embodiment, the second coating layer 42 could also be applied to the exterior surface of the building block instead of, or in addition to, the first coating layer. 15 The building block 10 has at least one aperture for receiving a connector member 60 therethrough. According to some embodiments, the aperture(s) is provided on the side wall panel 33 of the building block 10, extending through the outer layer 30 and partially through a first pipe member 21 of the inner layer 20 of the building block 10. The connector 20 member 60 is designed to connect neighbouring blocks 10 side by side and/or to act as a spacer between rows of connected building blocks 10 when they are used as a dual-layered wall for a dwelling/building. The connector member 60 is intended to be easy to use, allowing the blocks to 2849292V1 2011-01-12 19:23 PRIVATE 0394088294 » P 16/23 2011200110 12 Jan 2011 11 blocks 10 and cured, the connector member 60 is secured in plac^ building blocks 10 are securely connected. It is envisaged that the Invention can be used as an alte bricks used in a brick veneer house, reverse brick veneer hod 5 double brick house. That is, the invention may perform the same and function as what bricks would otherwise provide abovementioned dwelling styles. For example, in a "double bri house, the invention would be used to provide a double layer and one external) of building blocks separated by an air space, 10 "brick veneer" style house, the invention would provide for o However, the single layer embodiment is preferred. It is envisage^ building block using in a single layer arrangement would be thi that used in a double layer arrangement to provide additional strei According to some embodiments of the present invent)! 15 envisaged that the building blocks can be reinforced to support of the building block once the building block has been installed with concrete. It is envisaged that the reinforcement can be in the bar having a first end which is inserted half-way into a concrete and a second opposing end which extends upwardly into the buikji 20 to link the building block to the concrete slab. However, it is envi any other suitable form of reinforcement can also be used. Hence, the present invention provides a solution for allevj problems of the prior art by providing a building block that is cos and easy to use, while at the same time retaining the desired q and the rjnative to se, or a purpose in the " styled internal \k/hile in a (liter wall. that the &er than rjgth. bn, it is e weight and filled form of a Floor slab ing block surged that ating the effective ualities of ck (onij til COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 2011-01-12 19:24 PRIVATE 0394088294 » P 17/23 2011200110 12 Jan 2011 12 other building materials, such as insulation and aesthetic appeal. The building block of the present invention is designed to reduce the amount of energy required to heat and cool dwellings or properties built with the building blocks thus, offering environmental benefits, in addition, the building block of the present invention is also designed to offer acoustic advantages over other building materials, reducing the intrusion of external sounds as well as reducing the transmission of noise within the hoiise.

While we have described herein a particular embodiment of a building block for houses and similar structures, it is further envisaged that 10 other embodiments of the invention could exhibit any nurrber and combination of anyone of the features previously described. However, it is to be understood that any variations and modifications can f>e made without departing from the scope thereof, COMS ID No: ARCS-305903 Received by IP Australia: Time (H:m) 21:06 Date (Y-M-d) 2011-01-12 13 2011200110 21 Sep 2016

While we have described herein a particular embodiment of a building block for houses and similar structures, it is further envisaged that other embodiments of the invention could exhibit any number and combination of anyone of the features previously described. However, it is 5 to be understood that any variations and modifications can be made without departing from the scope thereof.

In this specification, the terms “comprise”, “comprises”, “comprising” or similar terms are intended to mean a non-exclusive inclusion, such that a system, method or apparatus that comprises a list of elements does not 10 include those elements solely, but may well include other elements not listed. 2849292v1

Claims

CLAIMS:

1. A building block comprising: an outer layer comprising a plurality of vertically oriented hollow pipe members provided between at least one outer wall panel and at least one inner wall panel; an inner layer comprising a plurality of vertically oriented hollow pipe members, whereby the inner layer is in direct contact with the outer layer; and at least one connector member for connecting one or more adjacent building blocks together; wherein the vertically oriented hollow pipe members of the inner layer and the outer layer are cylindrical in shape and adapted to receive concrete.
2. The building block of claim 1, wherein the building block is made of a composite fibre material including, but not limited to, a mixture of cardboard and continuous roving glass, lightweight sand, resin, fibreglass or the like.
3. The building block of any preceding claim, wherein the outer layer comprises two side wall panels.
4. The building block of claim 3, wherein the outer wall panel, the inner wall panel and the two side wall panels are positioned so that the outer layer forms a rectangular shape for the building block.
5. The building block of claim 3 or claim 4, wherein the height of the outer wall panel, the inner wall panel and the two side wall panels of the outer layer is higher than that of the plurality of pipe members of the inner layer such that the inner layer is completely covered to provide the appearance of a solid building block.
6. The building block of any preceding claim, wherein the outer layer has at least one first coating layer applied to its surface.
7. The building block of claim 6, wherein the first coating layer is a gelcoat material applied to the outer wall panel of the outer layer of the building block.
8. The building block of claim 6 or claim 7, wherein a second coating layer is a plasterboard/plasterboard paper layer applied to an inner wall of the inner layer of the building block.
9. The building block of any preceding claim, wherein the building block further comprises at least one aperture adapted to receive the connector member therethrough.
10. The building block of claim 11, wherein the at least one aperture is provided on the side wall panel(s) of the building block, extending through the outer layer and partially through one of the plurality of first pipe members of the inner layer of the building block.
11. The building block of any preceding claim, wherein the connector member is in the form of a rod-like member for connecting adjacent rows of building blocks in a horizontal and/or vertical direction.
12. The building block of any preceding claim, wherein the plurality of pipe members is produced via a filament winding process.
13. The building block of claim 12, wherein the filament winding process involves a single layer of composite fibre being immersed in a resin bath, where the layer is coated with low or medium molecular weight reactants to provide an impregnated layer of composite fibre.
14. The building block of claim 13, wherein the resin is an orthophthalic neopentyglycol unsaturated polyester resin.
15. The building block of claim 12 or claim 13, wherein the plurality of pipe members is formed by winding the impregnated layer of composite fibre around a mandrel (mold core) in a controlled pattern to form the shape of the pipe members and cured.