Patent Publication Number: US-2021189723-A1

Title: Construction element

Description:
TECHNICAL FIELD 
     The present invention relates to a construction element allowing, for example, the construction of a wall or a vertical panel. 
     PRIOR ART 
     The document U.S. Pat. No. 3,885,363 A describes a construction element comprising a preformed insulation insert placed in a cavity of a concrete frame. Such construction elements can be used to construct a wall by assembling them with mortar for example. This assembly requires precision to ensure that the construction elements are properly aligned and time to place the mortar and also because of this precision. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide a construction element that is easy and quick to assemble and does not require mortar. 
     The invention provides a construction element comprising:
         a frame comprising a cavity opening through an upper opening and a lower opening, and   a block arranged to move in a first direction in the cavity under the action of an external pressure and to remain at least partially blocked in the cavity in the absence of external pressure,       

     wherein an upper end of the block is adapted to engage the upper opening of the cavity and is adapted to engage the lower opening of the cavity. 
     In the present invention, when two frames are superimposed so that the cavities are aligned, the upper end of the block may be engaged in the cavity of the upper frame while the lower end of the block may be engaged in the cavity of the lower frame. Thus, the block itself serves as a means for fixing and aligning between the construction element and a second identical construction element. It is therefore not necessary to put mortar between two superimposed construction elements. 
     Since the block is blocked in the cavity when no force other than gravity is exerted on it, the fixing between two superimposed construction elements is particularly strong. The two frames can be considered to be fitted tightly onto the block. 
     The fact that the block can be moved in the frame gives flexibility on the relative position of the block with respect to the frame. In addition, it allows each block to be pushed into the frame as far as possible during transport, in order to reduce the transport volume and the block to be at least partially protected by the frame during transport and on the construction site before construction. 
     The block remains locked in the cavity by lateral mechanical compression when it is not subjected to pressure in the first direction, but it moves relative to the frame when it is subjected to external pressure in the first direction. The block is designed to be inserted snugly into the cavity. When a wall is constructed with the construction element, the first direction is preferably a vertical direction. 
     The block can for example be made of a compressible material or have a surface structure allowing this movement under pressure and blocking in the absence of pressure. 
     The block is such that the action of a force causes it to slide in the cavity, but if it is not subjected to forces other than gravity it is immovably wedged in the cavity. Preferably, human force is sufficient to make the block slide into the frame. 
     For the purpose of this paper, an “external pressure” is sufficient pressure to move the block in the cavity. The force corresponding to the external pressure is greater than the force of gravity, so that the block remains immobilized by the frame when it is subjected only to the action of gravity. The external pressure is preferably a pressure in the first direction. 
     Preferably, the construction element is arranged to weigh less than 20 kg, more preferably less than 15 kg. For example, a prototype of a 300 mm×300 mm×300 mm construction element in which the frame is made of OSB and the expanded polystyrene block is about 4 kg. 
     The frame is preferably an object formed of a plurality of flat panels parallel to the first direction, so as to delimit the cavity in any direction perpendicular to the first direction. For example, each panel can be formed of a plate. The frame is preferably devoid of grooves on its outer surface. 
     The cavity is designed to allow the block to slide from its lower end to its upper end. 
     For example, the frame can be between 100 and 800 mm high, preferably about 300 mm. For example, the frame can be between 100 and 800 mm deep, preferably about 300 mm. For example, the frame can be between 100 and 800 mm wide, preferably about 300 mm. The panels of the frame are for example between 10 and 30 mm thick, preferably about 18 mm. The frame can for example be cubic. 
     One function of the frame is to provide the outer panels of the wall. It also allows the permanent fixing of several construction elements together to form modules that can be removed from each other. A wall can thus be constructed by placing modules offset from each other, for example staggered. 
     The frame is preferably made of a heat-insulating material. 
     Preferably, the upper opening of the cavity is located on an upper end of the frame and the lower opening of the cavity is located on a lower end of the frame. Preferably, the upper opening of the cavity is the same as the lower opening of the cavity. 
     The block is preferably a solid and filled object. The block is preferably formed in a homogeneous and isotropic material. The block is thermally insulating. For example, the block can be made of or comprise expanded polystyrene, graphitized expanded polystyrene, or polyurethane foam. The block may for example be made of one or more materials having a Young&#39;s modulus greater than 1.0 GPa, preferably between 2.0 and 4.0 GPa, more preferably between 2.5 and 3.5 GPa. The block is rigid enough to block the frame when partially engaged in the cavity of the frame. The block is preferably made of a flame-resistant material. 
     The block preferably extends between all the lateral panels of the frame so as to be in contact with them. When partially housed in two superimposed frames, the block is preferably such that it extends between all the lateral panels of the two frames, so as to be in contact with them. 
     Preferably, the height of the block is equal to the height of the frame. 
     Preferably, the block extends laterally between several parts of surfaces forming a triangle, rectangle or square. These surface parts preferably comprise a flat part intended to contact the inner surface of the cavity and a recessed part to form a chamfer at the upper end of the block. 
     For example, the block may be between 100 and 800 mm high, preferably about 300 mm. For example, the block can be 100 to 800 mm deep, preferably about 263 mm. For example, the block can be between 100 and 800 mm wide, preferably about 263 mm. The width of the block is preferably equal to its depth. 
     One function of the block is to form the male part of the arrangement by interlocking while the frames form female parts. Another function of the block is to provide excellent thermal and sound insulation. 
     In an embodiment of the invention, the cavity and the block are such that the block can enter the cavity through its lower opening and exit through its upper opening. 
     Thus, it is possible to slide the block completely out of the cavity. 
     In an embodiment of the invention, the difference, taken in absolute value, between at least one lateral extent of the cavity and a corresponding lateral extent of the block measured when the block is outside the cavity is less than 3 mm, preferably less than 2 mm, more preferably less than 1 mm. 
     In other words, the lateral extent of the block may be less than, greater than, or equal to the lateral extent of the cavity, but the difference between these two extents is preferably less than 3 mm, 2 mm, or 1 mm. 
     Thus, the block is intended to be inserted in a particularly tight fit in the cavity. 
     For the purpose of this document, a “lateral extent” of an element can be, for example, its length, width, depth. As the block is intended to be at least partially engaged in the cavity, a lateral extent of the block generally corresponds to a lateral extent of the cavity: for example, the width of the block corresponds to the width of the cavity and the depth of the block corresponds to the depth of the cavity. 
     The absolute value of the difference between the lateral extent of the block and the corresponding lateral extent of the cavity is preferably less than 1% of the lateral extent of the block, more preferably less than 0.5% of the lateral extent of the block. 
     The block may be sufficiently compressible laterally so that its lateral extent decreases when it is at least partially engaged in the cavity. 
     In an embodiment of the invention, the difference, in absolute value, between the width of the cavity and the width of the block measured when the block is outside the cavity is less than 3 mm, preferably less than 2 mm, more preferably less than 1 mm and/or the difference, in absolute value, between the depth of the cavity and the depth of the block measured when the block is outside the cavity is less than 3 mm, preferably less than 2 mm, more preferably less than 1 mm. 
     In an embodiment of the invention, the upper end of the block is chamfered and/or corners of the upper end of the block are rounded. 
     This chamfer makes it possible to reduce the width and/or the depth of the block at its upper end so that the block can be easily introduced into the cavity through the lower opening of the frame, in particular if the lateral dimension of the block outside the cavity is close to the corresponding lateral dimension of the cavity. For example, the chamfer can be about 1 cm. 
     In an embodiment of the invention, the frame comprises lateral panels delimiting the cavity laterally, and the block is intended to be in mechanical contact with all the lateral panels of the frame when it is blocked, at least partially, in the cavity. 
     This ensures a particularly strong blocking and a particularly good thermal insulation, since the thermal insulation effect of the block extends over the entire width and depth of the construction element. Preferably, the block is in mechanical contact with all the lateral panels for at least 50% or 80% of the height of the block that is in the cavity. 
     In an embodiment of the invention, the height of the frame is substantially equal to the height of the block. For the purpose of the present invention, the “height” of an object is preferably the maximum distance between the lower end and the upper end of the object. 
     In an embodiment of the invention, the frame and the block have a polygonal, hexagonal, rectangular, triangular or square section in a plane perpendicular to the first direction. The horizontal section of the frame and the block are preferably rectangular, more preferably square. 
     In an embodiment of the invention, the cavity is delimited by flat surfaces parallel to the first direction. 
     Thus, the flat surfaces that delimit the cavity are not inclined with respect to the first direction. This avoids, in particular, any upward or downward narrowing of the cavity. 
     In an embodiment of the invention, the frame is at least partially made of wood and/or polymer. 
     The frame may be in any material comprising wood. It can for example be made of oriented strand board called, which are sometimes known as OSB. The MDF is also possible. The frame can also be made of a polymer. 
     Preferably, the frame does not comprise concrete. Indeed, concrete panels should be much thicker than wood and/or polymer panels, which would make the construction element heavy. 
     The invention furthermore provides an assembly comprising a first and a second construction elements, wherein the frame of the second construction element is placed on the frame of the first construction element and the block of the first construction element is mechanically blocked in the cavity of the frame of the first construction element and in the cavity of the frame of the second construction element. Preferably, this assembly does not comprise any gluing means between the frame of the first construction element and the frame of the second construction element. 
     The invention further provides a construction module comprising a first and a second construction elements according to any embodiment of the invention, and wherein the frame of the first construction element is laterally fixed, for example by screwing and/or gluing, to the frame of the second construction element. The different construction elements of a module are preferably identical. 
     In an embodiment of the invention, the construction module further comprises a third construction element according to any embodiment of the invention laterally fixed to the frame of the second construction element. Preferably, the three construction elements of the module are aligned or arranged in a corner. 
     The invention further provides a wall comprising at least three construction modules according to any embodiment of the invention, at least a first one of the construction modules comprising:
         a first block located on the one hand in a first cavity of the first construction module and on the other hand in a cavity of a second of the construction modules, and   a second block located on the one hand in a second cavity of the first construction module and on the other hand in a cavity of a third of the construction modules.       

     The modules are thus arranged in offset with respect to each other in order to obtain a particularly solid wall. In addition, the wall may also comprise uprights fixed to several construction modules. This increases the stability of the wall. 
     The wall may also comprise a board to which some of the construction elements are fixed, with the frame of the construction elements fixed to the board comprising a lower cutout that receives at least an upper part of the board. The board can be called wall plate. 
     The invention further proposes a building comprising at least one construction element according to any embodiment of the invention, or a module according to any embodiment of the invention, or a wall according to any embodiment of the invention. 
     The invention further proposes a method of constructing a wall or a vertical panel and comprising the steps of:
         (a) providing a first frame comprising a cavity opening through an upper opening and a lower opening,   (b) providing a second frame comprising a cavity opening through an upper opening and a lower opening,   (c) providing a block arranged to move in a first direction in the cavity of the first frame under the action of external pressure and to remain at least partially blocked in the cavity of the first frame in the absence of external pressure, and to move in the first direction in the cavity of the second frame under the action of external pressure and to remain at least partially blocked in the cavity of the second frame in the absence of external pressure, and   (d) engaging the block in the upper opening of the cavity of the first frame and in the lower opening of the cavity of the second frame.       

     The advantages mentioned for the device apply mutatis mutandis to the method. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       Other characteristics and advantages of the invention will appear when reading the following detailed description, for the understanding of which one will refer to the annexed figures among which: 
         FIG. 1 a    is a vertical section of a construction element according to an embodiment of the invention, 
         FIG. 1 b    is a horizontal section of a frame forming part of a construction element according to an embodiment of the invention, 
         FIG. 1 c    is a horizontal section of a block forming part of a construction element according to an embodiment of the invention, 
         FIG. 1 d    is a three-dimensional view of a construction element according to an embodiment of the invention, 
         FIG. 2  is a vertical section of an assembly of two construction elements according to an embodiment of the invention, 
         FIG. 3  is a three-dimensional view of a construction module according to an embodiment of the invention, 
         FIG. 4  is a vertical section of a construction module according to an embodiment of the invention, 
         FIG. 5 a    is a vertical section of an assembly according to an embodiment of the invention, 
         FIG. 5 b    is a vertical view of a frame that can be used in the assembly of  FIG. 5   a,    
         FIG. 6  is a vertical view of a wall according to an embodiment of the invention, and 
         FIG. 7  is a vertical view of a wall according to an embodiment of the invention comprising a window. 
     
    
    
     EMBODIMENTS OF THE INVENTION 
     The present invention is described with particular embodiments and references to figures but the invention is not limited by them. The drawings or figures described are only schematic and are not limiting. 
     In the context of this document, the terms “first” and “second” serve only to differentiate between the different elements and do not imply any order between these elements. 
     In the figures, identical or similar elements may bear the same references. 
       FIGS. 1 a  to 1 d    illustrate an example of frame  1  and an example of block  2  which may be part of a construction element  10  according to an embodiment of the invention. 
     For the purposes of this description, the first direction  101  is preferably considered to be a vertical direction. 
     The frame  1  comprises a cavity  22 . The cavity  22  passes through the frame  1  between an upper end of the frame  1  and a lower end of the frame  1 . The cavity  22  is opened by an upper opening  22   a  and a lower opening  22   b  opposite each other. 
     The frame  1  comprises lateral panels  23 , for example two first panels  1   a  (front and back panels) and second two panels  1   b  (left and right panels). It is preferable that the second panels  1   b  be blocked laterally between the first two panels  1   a . This can be seen in  FIG. 1   b.    
     The block  2  is arranged to be mechanically wedged in the cavity  22  when no external pressure is exerted on it, and to move in the first direction  101  when it is subjected to external pressure capable of moving it in the first direction  101 . 
     The block  2  has an upper end  25  and a lower end  26 . Preferably, the upper end  25  of the block  2  is arranged to be engaged, according to the first direction  101 , in the upper opening  22   a  and the lower opening  22   b  of the cavity  22 . The upper end  25  of the block  2  can thus engage in the upper opening  22   a  of the cavity of a first frame  1  and in the lower opening  22   b  of the cavity of a second frame  1 , identical to the first frame  1 , and located above the first frame  1 . 
     More preferably, the entire block  2  can be inserted into the cavity  22  following the upper end  25  of the block  2 . Preferably, the block  2  has a chamfer  21  on one edge of its upper end  25 , so that it can be easily inserted into the frame  1 . 
     Preferably, the block  2  is slidable in the frame  1  in the first direction  101 , and its dimensions are chosen so that, in the absence of pressure, the block  2  is mechanically blocked in the frame  1 . 
     Preferably, the frame  1  and the block  2  are of square horizontal section, but it could have another shape while remaining within the purpose of the invention. 
       FIG. 1 a    shows the block  2  partially inserted in the cavity  22  of the frame  1 , so that it protrudes from the cavity  22  at its upper end  25 . This figure illustrates the height  51  of the frame  1  and the height  52  of the block  2 . 
       FIG. 1 b    illustrates the width  53  of the cavity  22  and the depth  55 .  FIG. 1 c    makes it possible, in particular, to illustrate the width  54  of the block  2  and its depth  56 . 
       FIG. 2  shows two stacked construction elements  10 . The block  2  of the lower construction element  10  is partially engaged, with its upper end  25 , in the frame  1  of the upper construction element  10 . The construction elements  10  are assembled by interlocking one on top of the other, offsetting the block  2  with respect to the frame  1 , so that the block  2  is partially received in two frames located one on top of the other. 
       FIGS. 3 and 4  illustrate construction modules  100  according to embodiments of the invention. The construction module  100  comprises several construction elements  10  according to the invention, for example two construction elements  10  for the module  100  illustrated in  FIG. 3  and three construction elements  10  for the module  100  illustrated in  FIG. 4 . The construction elements  10  are preferably fixed together via a lateral panel at a junction  3  between two frames  1 , so that they are at the same height. Preferably, a single plate forms the front panels  1   a  of the frames  1  of several construction elements  10  and a single plate forms the rear panels  1   a  of the frames  1  of several construction elements. Preferably, the blocks  2  of the different construction elements can be moved independently. 
       FIG. 5 a    shows a possible assembly with a construction element  10  according to an embodiment of the invention. This assembly is in particular advantageous for forming the lowest level of a wall. For example, this assembly may comprise base blocks  8 , a hermetic layer  7 , a board  5  and construction elements  10 . 
     The base blocks  8  are for example Ytong blocks aligned in a direction perpendicular to the plane of  FIG. 5 a   . The sealing layer  7  is for e.g. made of an EPDM (ethylene-propylene-diene monomer) foil. The board  5 , which can be called a wall plate, is preferably fixed by means for fixing or screws  9  to the base blocks  8 . The construction elements  10 , with a frame  1  where the second panels  1   b  are shortened as shown in  FIG. 5 b   , are arranged so that the board  5  is engaged between the first panels  1   a  and preferably abuts against the lower ends of the second panels  1   b . Means for fixing or screws  6  may be used to fix the first panels  1   a  to the board  5 . 
       FIG. 5 b    illustrates the frame  1  whose second panels  1   b  are shorter than the first panels  1   a , so as to create a passage  16  arranged to receive at least the upper part of the board  5 . 
       FIG. 6  illustrates a wall  200  comprising modules  100 ,  100   a ,  100   b ,  100   c  according to the embodiment of the invention and uprights  4 . For reasons of clarity, only certain blocks are shown. They are shown as dotted lines to indicate that they are hidden inside the modules. 
     The modules  100  are preferably arranged vertically offset so that a first part of an upper module rests on a first lower module and a second part of an upper module rests on a second lower module. In addition, this allows first  120  and second  130  blocks belonging to a first module  100   a  to be located partially in the first module  100   a  and partially in a second module  100   b  and third module  100   c , respectively. This results in a mechanical coupling between the second  100   b  and third  100   c  modules via the first  100   a  module. 
     At the top of the wall  200 , for example, it is possible to cut off the upper ends of the protruding blocks, or to provide blocks of lower height, in order to finish the wall with a horizontal surface. 
     The uprights  4 , which can also be called rafters, are fixed, for example screwed or nailed, to several superimposed construction elements. 
       FIG. 7  shows a part of wall comprising a window  11 . The window  11  is a part of open wall. It is delimited, for example, by a lower board  14  at the bottom, an upper board  15  at the top and lateral construction elements  10 . The upper board  15  preferably rests on second panels  1   b  of two of these lateral construction elements, which can be called first lateral construction elements  10   c . The wall also comprises a lintel  12  located above the tureen board  15  and these first lateral construction elements  10   c . The lintel  12  is a construction module in which central construction elements  10   a  have their second two panels  1   b  shorter than their first two panels  1   a , and end construction elements  10   b  have one of their second two panels  1   b  shorter than their first two panels  1   a . The blocks  2  of the first lateral construction elements  10   c  are partially inserted into the cavities of the end construction elements  10   b.    
     In other words, the invention relates to a construction element  10  comprising a frame  1  and a block  2  that can slide in the frame  1  when subjected to an external force. The block  2  can thus form a tenon between two superimposed frames  1  forming mortises. Construction elements  10  fixed together laterally form modules  100  that can be assembled offset from one level to the other to form a wall. 
     The present invention has been described in relation to specific embodiments, which are of purely illustrative value and should not be considered as limiting. Generally speaking, the present invention is not limited to the examples illustrated and/or described above. The use of the verbs “comprise”, “include”, “consist”, or any other variant, as well as their conjugations, can in no way exclude the presence of elements other than those mentioned. The use of the indefinite article “a”, “an”, “one”, or the definite article “the”, to introduce an element does not exclude the presence of a plurality of such elements. The reference numbers in claims do not limit their scope.