AU2011201980A1 - A building module - Google Patents

Abstract

The present invention relates to a clip 100. The clip comprises a first end portion 110 for engaging with a side of a cavity of a building block. A second end portion 5 120 engages with the aperture or groove formed in an edge of a panel, A resilient central portion 130 is located between the first end portion 110 and second end portion 120. 110l 100

Description

AUSTRALIA Regulation 3.2 Patents Act 1990 Complete Specification DIVISIONAL APPLICATION APPLICANT: RB Products Pty Ltd Invention Title: A BUILDING MODULE The following statement is a full description of this invention, including the best method of performing it known to me: A Building Module 5 FIELD OF THE INVENTION The present invention relates to a building module. More particularly, the present invention relates to a building module for use in the construction of a wall and to a method of forming a building module for use in the construction of a wall. 10 In a further aspect, the invention is directed to a clip for use in the construction of a building module. The invention will herein be described in a non-limiting manner with reference to 15 the specific field of use. BACKGROUND OF THE INVENTION The use of building modules for the construction of walls such as a retaining wall 20 or wall for a building or the like is well known. Typically, such walls are constructed using a building block made of stone or cast material such as cement or a cement sand combination. In order to improve the visual appearance of such a wall, a panel is often 25 attached to a building block or blocks. Panels which are fixed to a building block

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or blocks typically consist of large, relatively thin slabs of stone or other material of greater aesthetic appeal than the blocks from which the wall is constructed. The present invention aims to provide a novel building module and a method of 5 forming a building module. In the preferred embodiment, the building module is constructed using a combination of means to fix a panel to a building block which advantageously allows for rapid construction of a building module and eliminates the risk of a panel shearing from a building block. 10 In a further preferred embodiment of the present invention, a clip is provided as one component of the combination of means used to fix a panel to a building block. SUMMARY OF THE INVENTION 15 In one aspect, the present invention provides a building module and a method of forming a building module. A further aspect of the invention provides a clip as defined in the claims for use in 20 forming a building module. 2 Other preferred features of the various aspects of the invention will be apparent from the dependant claims and from the following description of the preferred embodiment. 5 BRIEF DESCRIPTION OF THE DRAWINGS The various aspects of the invention will now be described in a non-limiting manner with respect to a preferred embodiment of the invention in which: 10 FIG 1 is an exploded view of the building module; FIG 2 is top perspective view of the assembled building module; FIG 3A is a perspective view of an embodiment of the panel of the building module; FIG 3B is a perspective view of an alternative embodiment of the panel of the 15 building module; FIG 3C is a perspective view of another alternative embodiment of the panel of the building module; FIG 4A is a perspective view of an embodiment of a mechanical device of the building module in the form of a clip; 20 FIG 4B is a perspective view of an alternative embodiment of a clip; FIG 5 is an exploded view of an alternative embodiment of the building module of the present invention; 3 FIG 6 is top perspective view of an alternative embodiment of the building module of the present invention; FIG 7A is a perspective view of an embodiment of a mechanical device of the building module in the form of a brace; and 5 FIG 7B is a perspective view of an alternative embodiment of a brace. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS With reference to FIGS 1 and 2, a building module 10 including a building block 10 20 and a panel 40 is shown. The building block 20 has at least one face 22 upon which the panel 40 is to be affixed. The panel 40 is fixed to building block 20 by the combination of one or more strips of double sided tape 60, an adhesive 80 applied to one or more portions of at least one face 22, and additionally one or more mechanical devices fastenable to both the building block 20 and panel 40. 15 In a preferred form, the mechanical device is a clip 100 fastenable to the building block 20 and panel 40. However, alternative mechanical devices such as a brace shown in FIGS 7A-7B, or a staple or pin (not shown), are also envisaged. In the preferred embodiment of FIGS. 1 and 2, the building block 20 includes two 20 cavities 24, each capable of receiving a mechanical device in the form of a clip 100. It will be understood by the skilled person that building blocks such as that shown in FIG 1 or 2 may comprise one or more such cavities of varying size and depth. 4 The building block 20 may be lightweight concrete or plastic or any other man made material, In a preferred embodiment, the building block 20 comprises cast material, extruded material or natural stone. Preferably, the cast material is chosen from the group comprising concrete, clay, mud, aerated Hebal@ 5 concrete, re-constituted stone or sand, polymer, recycled materials or combinations thereof. Masonry building blocks for retaining walls typically are cast in metal moulds to form a unitary block. The material may be dried or fired as appropriate. In one preferred embodiment, the building block 20 is an aerated HebeI@ concrete block from CSR Limited. 10 In another preferred embodiment, building block 20 comprises a concrete masonry building block sold under the name BesserTM from Boral Besser Pty Ltd. These building blocks are principally constructed of a compressed mixture of sand, cement, aggregate and water, with large recesses formed in the interior 15 of the block to reduce the weight of the building block 20 without compromising structural integrity. A further preferred embodiment uses a concrete masonry building block 20, sold under the name of BenexBlockTM from Benex Technologies Pty Ltd made using 20 three different mixes to provide desired fire rating, water proofing, thermal and acoustic properties. 5 In FIGS- I and 2, panel 40 is shown with an edge 42 including one or more apertures 44 which serve to receive and retain clip 100 to the panel 40, as will be explained in more detail below. The apertures 44 are sized and spaced so that once the panel 40 is correctly aligned with the building block 20, the apertures 44 5 substantially align with cavities 24 of the building block 20, FIG 1 also illustrates the preferred mechanical device for the present invention in the form of a plurality of clips 100. Each clip 100 comprises a first end portion 110 for engaging with the building block 20, a second end portion 120 for 10 engaging the panel 40, and a resilient central portion 130. The resilient central portion 130 provides tension between the first end portion 110 and the second end portion 120 so that the clip 100 is fastened onto the building block 20 and securely retains panel 40 to building block 20. 15 In constructing the building module 10, resilient central portion 130 of the clip 100 is adjusted such that the distance between the first end portion 110 and the second end portion 120 of the clip is no more than the distance from the side of the cavity 24 in the building block 20 closest to the panel 40, to the apertures 44 of the panel 40 when the panel 40 is pressed to the building block 20. Once the 20 double sided tape 60 and the adhesive 80 are applied to the building block 20, clip 100 is fastened to the cavity 24 of the building block 20 and apertures 44 of panel 40 by slightly biasing open the clip 100 and pressing the clip to engage with the cavity 24 and aperture 44 respectively. The clip 100 may then be 6 released and the resilient central portion 130 provides tension between the first end portion 110 and second end portions of the clip 120 to retain the clip 100 in situ. The application of double sided tape 60 and adhesive 80 to the building block 20 or panel 40 increases the distance the clip 100 needs to span between 5 the cavity 24 and aperture 44. This ensures that the resilient central portion 130 of the clip is tensioned, thereby retaining the clip 100 in position. It will be understood that the mechanical device may be any appropriate mechanical device for exterior work. Further examples of appropriate 10 mechanical devices envisaged by the present invention also include braces, pins, and staples. The clips 100 are described in more detail below with reference to FIGS 4A-4B. Double sided tape 60, best shown in FIG 1 may be any suitable industrial tape for 15 use in adhering together two bodies which may be exposed to the weather. As would be understood by those in the art, "double sided" tape refers to a substrate in the form of a tape, film or foil or the like having an upper and lower surface, with each surface carrying an adhesive. In this manner, the double sided tape 60 may be used to affix two bodies together. One example of a suitable double 20 sided tape is the 3M T M

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T M Tape, in particular tape number 4991 which typically affixes to surfaces in under three minutes. 7 Whilst FIGS 1 shows the double sided tape 60 extending vertically over the full depth of the building block 20, the length of double sided tape 60 will typically be shorter for cost efficiency. Typically, two 100 mm length strips of double sided tape 60 are preferred. In alternative embodiments, depending on the weight of 5 the panel 40, the number of strips of double sided tape 60 applied to the building block 20 may vary. Similarly, the orientation and length of each strip of double sided tape 60 applied to the building block 20 may vary. In applying the double sided tape 60 sufficient 10 space must be left to apply a suitable amount of adhesive 80 to adhere the panel 40 to the building block 20, and sufficient double sided tape 60 applied to affix and hold the panel 40 to the building block 20 without the aid of the adhesive 80 or clips 100. 15 FIG 1 shows a building block 20 having adhesive 80 applied to a plurality of locations on at least one face 22 of the block. In an alternative embodiment (not shown), the adhesive 80 may be applied to the surface of the panel 40 which is to bond to the building block 20. As would be appreciated by those of skill in the art, adhesive 80 applied to the building block or panel must be suitable for use in 20 exterior bonding and includes bonding agents such as a resin, epoxy or silicon based adhesives. 8 In a particularly preferred embodiment of the invention, a silicon based adhesive such as Geniosil@N70 from Wacker Chemicals Australia Pty Ltd., is applied evenly to the at least one face 22 of the building block 20. Such an adhesive 80 is preferable applied to the building block 20 or panel 40 in a manner to cover an 5 area of approximately 4cm 2 of the surface to which the adhesive 80 is being applied. It should be noted that throughout the present specification the use of the term "adhesive" refers to an adhesive which is fluid and may be extruded onto a 10 surface or surfaces which is/are to be adhered to another. This is taken to be distinct from any reference to the adhesive properties of the double sided tape, which refers to an adhesive which is carried on a substrate in the form of a tape, film or foil or the like as previously described. 15 FIG 2 illustrates the assembled building module 10. Panel 40 is fixed to building block 20 in its desired position using the combination of the double sided tape 60, adhesive 80 (not visible) and a plurality of clips 100. Each clip 100 is fastened at one end to a cavity 24 of the building block 20 and at its second end portion to the panel 40 at an aperture 44. 20 In this instance, panel 40 is mounted squarely onto the building block 20 and advantageously retained in this position by the double sided tape 60 and clip 100 whilst the adhesive 80 cures to its optimum strength. 9 With reference to FIGS 1 and 2, the building module 10 is preferable constructed in accordance with the following method. 5 One or more strips of double sided tape 60 are fixed to at least one face 22 of building block 20. Adhesive 80 is then placed on at least one face 22 of the building block 20. Panel 40 is pressed to building block 20 so that the one or more strips of double sided tape 60 and adhesive 80 are able to adhere to the panel. One or more mechanical devices in the form of a clip 100 are fastened to 10 the building block 20 and to panel 40 to retain the panel to the building block. Preferably, two strips of double sided tape 60 having length substantially the same as the height of the building block, are fixed in a substantially vertical orientation onto the at least one face 22. It is also preferred that adhesive 80 is 15 evenly distributed across the at least one face 22 in at least three locations. Additionally it is preferred that at least two clips 100 are fastened such that the respective first end portions 110 of each clip fastens to the respective side of at least two cavities 24 in the building block 20, and the respective second end portion portions 120 engage with respective apertures 44 on an edge 42 of the 20 panel 40. As will be appreciated by the skilled person, the clips 100 may equally be applied to the top side or bottom side of the building block 20, with the orientation of the panel 40 such that the second end portions of the clip 120 engage with the apertures 44 of the panel. 10 The combination of the double sided tape 60, adhesive 80, and mechanical device advantageously allows for rapid manufacture of the building module 10 without giving up any long term strength in the bond between the panel 40 and 5 the building block 20. This is because double sided tape 60 typically cures to its full adhesive strength in less than a few minutes. For example, the particularly preferred double sided tape, 3MTM VHBTM Tape, mentioned above reaches its full bond strength instantaneously upon the panel 40 being pressed upon building block 20. Once the double sided tape 60 has cured, the panel 40 is no longer 10 moveable with respect to the building block 20. Advantageously, this allows for the building block 20 and panel 40 to be rapidly assembled together aligned and permanently fixed in position. The additional fastening of the clip 100 to the building block 20 and panel 40 prevents any further movement between the building block 20 and the panel 40 before the adhesive 80 has set to its full 15 strength. The combination of double sided tape 60, adhesive 80 and a mechanical device to fasten the building block 20 and panel 40 provides a further advantage. Once the building block 20 and the panel 40 are pressed together, the mechanical 20 device provides pressure between the panel 40 and the building block 20, thereby eliminating the need for a person to physically provide such pressure whilst the double sided tape 60 is setting. 11 The mechanical device also advantageously provides a fail-safe mechanical mechanism to prevent the panel 40 shearing from the building block 20 if the chemical bond created by the double sided tape 60 and adhesive 80 were to fail over time. 5 In a preferred form of the invention, a sealant and/or primer may be applied to the building block 20 prior to assembly of the building module 10. Appropriate sealants include silicon based sealants, such as Dense-Crete Sealer and Clear Rock Sealer, both supplied by Mixa Pty Ltd. Appropriate primers include 3M M 10 94 Primer. The sealant or primer may be only applied to the areas to which the double sided tape and adhesive will be affixed, or to the whole of one face 22 of the building block 20. The sealant's or primer's primary functions are to improve the affixing of the double sided tape 60 and adhesive 80 to the building block 20 and inhibit moisture getting to the double sided tape or adhesive. A drying time 15 of typically 5 to 20 minutes is required depending on the sealant used, whilst the preferred primer for the present invention, 3M' TM 94 Primer, typically dries within 5 minutes at room temperature. FIGS 3A - 3C show alternative embodiments of the panel 40. As may be seen in 20 FIG 3A, panel 40 includes an edge 42 having two apertures 44 in the form of pre cut slots. In alternative embodiments the number of apertures may vary depending on the number of mechanical devices used to fix the panel 40 to the building block 20, not shown. Typically, there is at least one aperture 44 per 12 mechanical device to be fixed. In the preferred form, each aperture 44 is located on edge 42 so as to substantially align with a cavity 24 of building block 20, not shown. In an alternative embodiment, depending on the weight of panel 40, there may be a need for plurality of clips per building block cavity 24. Therefore, 5 panel 40 may have a plurality of apertures 44 located along its edge 42, so that two or more apertures 44 align with each respective cavity 24 located on a building block. In a preferred form of the invention, the panel 40 comprises natural or synthetic 10 material. For example, the panel may be chosen from the group consisting of stone (including but not limited to sandstone, bluestone, granite, marble), metal sheet, timber, glass, plastic, composite materials and combinations thereof. Composite materials include materials which combine other materials listed as well as other materials such as plastic. For example, a composite material could 15 be a mixture of stone and plastic wherein the stone has been crushed and dispersed in a plastic and then panels moulded from the stone plastic composite. The panel 40 may be of any convenient conformation and thickness. In a preferred embodiment the panel is 5 to 50 mm in thickness, more preferably 10 to 30 mm, or even more preferably 15 to 25 mm. 20 In another preferred embodiment, the panel 40 is also pre-sealed with a sealant or primer in a manner similar to that described above. Similarly, any surfaces of 13 the panel 40 which are exposed and accessible by the public may be coated with a suitable anti-graffiti coating. FIG 3B shows an alternative embodiment of a panel 40, wherein the edge 42 of 5 the panel includes a continuous groove 46 along the length of the panel 40. FIG 3C shows a further alternative embodiment of a panel 40, wherein the edge 42 of the panel includes a plurality of apertures in the form of holes 48 located along the edge so that they align with a respective cavity of a building block. 10 FIG 4A illustrates the preferred embodiment of the mechanical device of the present invention in the form of a clip 100. The clip comprises a first end portion 110 for engaging with a side of a cavity of the building block, not shown. A second end portion 120 engages with the aperture or groove formed in an edge 15 of the panel, not shown. A resilient central portion 130 is located between the first end portion 110 and second end portion 120. The resilient central portion 130 is preferably substantially semi-elliptical in shape. This allows the distance between the first end portion 110 and the second end portion 120 to be adjusted by varying the curvature of the ellipse, whilst maintaining the tension between the 20 first end portion 110 and second end portion 120 due to the resilience of the central portion 130. 14 Advantageously, by varying the distance between the first end portion 110 and the second end portion of the clip 100, a single clip may be used to fasten panels and building blocks of varying thickness to each other. The clip 100 is typically manufactured from spring stainless steel to provide the resilience required. 5 However, any suitable material as understood by the skilled person may also be used. FIG 4B illustrates an alternative embodiment of the clip 100 of the present invention. In this embodiment, clip 100 includes a first end portion 110, second 10 end portion 120 and central portion 130 as previously described. However, second end portion 120 further includes serrations 140 which allow the clip 100 to gain better purchase and prevent the clip 100 from being withdrawn from aperture 44, groove 46, or hole 48 of the panels 40 described above. 15 In a further embodiment of the present invention, serrations 140 may be replaced by a single barb (not shown) in the second arm 120 in order to prevent the clip 100 being withdrawn from the panel 40 once in place. As would be understood by those in the art, the mechanical device of the present 20 invention may also be in the form of any suitable mechanical fastener applicable to masonry, such as a staple or pin used to fasten one masonry component to another. 15 FIGS 5 - 7B illustrate an alternative embodiment of the present invention. In this embodiment the mechanical device of the building module 10 is in the form of a brace 200 which is fastened to an upper surface 26 of a building block 20, rather 5 than a cavity of the building block 20 as previously described. Brace 200 comprises a first arm 210 for fastening to the upper surface 26 of the building block 20, and a second arm 220 substantially perpendicular to the first arm, fastenable on to panel 40 of the building module 10. 10 In this embodiment, one or more strips of double sided tape 60 are fixed to at least one face 22 of a building block 20. Adhesive 80 is applied to one or more locations on at least one face 22 of the building block 20. Panel 40 is then pressed onto building block 20 so that the one or more strips of double sided 15 tape 60 and adhesive 80 are able to adhere to the panel. Once the panel 40 is pressed into position on building block 20, the second arm 220 of brace 200 is pressed into aperture 44 so that it is fastened to the panel. First arm 210 of the brace 200 is fastened onto an upper surface 26 of the building block, preferably using a screw 250, such as a self tapping concrete screw, which passes through 20 hole 230 in the first arm 210 of the brace. The brace 200 is described in more detail with reference to FIGS 7A - 7B below. 16 This embodiment of the present invention advantageously allows a panel 40 to be fixed to a building block 20 which does not have a cavity or cavities as shown in FIG 5. The use of a brace also allows a panel to be fixed to building blocks which has cavities irregularly spaced throughout the block, thereby hindering 5 alignment between a plurality of apertures on a panel with one or more cavities on a building block to receive other types of mechanical devices such as clips or staples. FIGS 7A-7B show further alternative embodiments of the mechanical devices 10 suitable for the present invention. The mechanical device shown is in the form of a brace 200 and screw 250. Brace 200 comprises a first arm 210 and a second arm 220 substantially at right angles to the first arm 210. The brace also includes a hole 230 in the first arm to receive the screw 250. Preferably hole 230 is countersunk to receive the screw 250. Typically, the brace 200 is manufactured 15 from stainless steel, whilst the screw 250 is preferably a self tapping concrete screw. Any other suitable masonry fastener may also be used. It will be understood by the skilled person that the length and width of the first arm 110 and second arm 120 may be varied to accommodate building blocks and panels of various size and weight. 20 As shown in FIG 7B, in one alternative embodiment, the second arm 220 of brace 200 may include serrations 240 which allows the second arm 220 of the brace to gain better purchase and prevent the brace 200 from being inadvertently 17 withdrawn from a panel as described above. In a further embodiment of the present invention (not shown), serrations 240 may be replaced by a single barb in the second arm 220 in order to prevent the brace 200 being pulled out from the panel once in place. 5 Throughout this specification and the claims, unless the context requires otherwise, the word "comprise" and its variations, such as "comprises" and "comprising," 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 10 group of integers or steps. The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that such art forms part of the common general knowledge in Australia, 15 18

Claims (11)

1. A clip which in use retains a panel to a building block, wherein the clip 5 comprises a first end portion for engaging the building block, a second end portion for engaging the panel, and a resilient central portion between the first and second end portions.

2. The clip according to claim 1 wherein the resilient central portion is 10 substantially curved.

3. The clip according to claim 2 wherein the resilient central portion is substantially semi-elliptical. 15

4. The clip according to any one of the previous claims wherein the resilient central portion lies in a plane which is substantially perpendicular to both the first end portion and the second end portion.

5. The clip according to claim 4 wherein the first end portion and the second 20 end portion extend on the same side of the plane as each other.

6. The clip according to any one of the previous claims wherein the first end portion is longer than the second end portion. 25

7. The clip according to any one of the previous clams wherein the first end portion is substantially parallel to the second end portion.

8. The clip according to any one of the previous claims wherein the second end portion further comprises a serrated portion for engaging the panel. 30

9. The clip according to any one of claims 1 to 7 wherein the second end portion further comprises a barb for engaging the panel. 19

10. The clip according to any one of the previous claims wherein the clip is made of spring stainless steel.

11. A clip substantially as hereinbefore described. 5 20