Patent Publication Number: US-2009217610-A1

Title: High insulation building system

Description:
FIELD OF THE INVENTION 
     The present invention relates to building systems and, in particular, to a building system which uses prefabricated building components with thermal insulation properties which minimises onsite construction time. 
     BACKGROUND ART 
     Typical building techniques for domestic dwellings and the like usually start from the floor up with the erection of a structural frame, typically timber or steel, Roof cladding and roof insulation are then added to the frame with small cladding being similarly applied to the frame with insulation also installed. An internal skin is provided to the walls and ceiling cladding is also usually provided, The process of assembling the frame, insulating and applying cladding inside and outside is highly labour intensive involving a number of skilled trades specialist, 
     OBJECT OF THE INVENTION 
     The genesis of the present invention is to provide a building system which is highly insulating and requires minimal labour for its installation onsite. At the very least the object is to provide an alternative to existing building components. 
     SUMMARY OF THE INVENTION 
     In accordance with a first aspect of the present invention there is disclosed a wall block comprising a substantially rectangular core of substantially rigid insulating material which forms structural load bearing elements in a constructed wall, and said block having cladding bonded to its lateral surfaces. 
     Preferably, the cladding is offset from the lateral surfaces with the cladding overhanging from lower lateral edges, the overhang portion abutting against the core of the block(s) on lower course. 
     Preferably, a longitudinal void is provided in the lower surface of the core along its length. Preferably the void takes the form of a centrally located slotted groove. 
     The preferred form also has at least one vertically extending void, the void extending from the longitudinal void to the upper surface of the core. Preferably, the vertically extending void has a frusto-conical, shape. In other preferred forms, the frusto-conical shaped void in a wall when formed from the blocks is formed by a pair. of semi frusto-conical grooves formed in the end surfaces of adjacent blocks. 
     Preferably, recesses are formed in the vertical edges of the core, the recesses being formed behind the cladding and being adapted to receive elongated joint seals to affect sealing of joint between adjacent blocks. 
     Preferably, the block has mating location devices on the upper and tower surfaces of the core. Preferably these mating location devices take the form of a plurality of mating lugs and recesses. Preferably the lugs and recesses are frusto-conical in shape. Preferably the mating location devices are configured in a pattern that enables stacking and alignment of the blocks in a number of ways. For example, the blocks can be stacked directly on top of another, stacked offset by half a block, (usually referred to as stretcher bond), and stacked block upon block with the blocks being offset by 90 degrees, thus forming a corner. 
     In a preferred form, the core has a protective strip bonded to the exposed surface not covered by the cladding. 
     Preferably, the outer lateral surface has a drainage channel provided adjacent the top surface of the core. 
     Preferably, the rigid insulating material is a polyurethane foam material, the cladding is a sheet of cement material, and the protective strip is formed from galvanized steel sheet material. 
     In accordance with a second aspect of the present invention there is disclosed a method of forming a wall, said method comprising the steps of laying courses of blocks on a floor structure, the blocks comprising a substantially rectangular core of substantially rigid insulating material which forms structural toad bearing elements in the constructed wall, with said block having cladding bonded to its lateral surfaces. 
     Preferably, the cladding is offset from the lateral surfaces with the cladding overhanging from lower lateral edges, the overhang portion abutting against the core of the block(s) on lower course, the method including the step of locating the overhanging cladding on the lowest course of blocks against or in the floor structure. 
     Preferably, a longitudinal void is provided in the lower surface of the core along its length. Preferably the void takes the form of a centrally located slotted groove. The preferred form also has at least one vertically extending void, the void extending from he longitudinal void to the upper surface of the core. Preferably, the vertically extending void has a frusto-conical shape. In other preferred forms, the frusto-conical shaped void in a wall when formed from the blocks is formed by a pair of semi frusto-conical grooves formed in the end surfaces of adjacent blocks. The frusto-conical voids are adapted to align in vertical voids for the height of the wall, whereby the vertical voids are adapted to receive elongated compression means used to compress tie course of blocks together. 
     Preferably, the elongated compression means is formed by elongate threaded rods and corresponding nuts and plate devices located at the top and lowest courses of blocks. 
     Preferably, the blocks have recesses which ere formed in the vertical edges of the core, the method including the steps of providing elongated joint seals to affect sealing of joint between adjacent blocks, the seals being inserted behind the cladding and in the recesses. 
     Preferably, the block has mating location devices on the upper and lower surfaces of the core. Preferably these mating location devices take the form of a plurality of mating lugs and recesses. Preferably the lugs and recesses are frusto-conical in shape. 
     In a preferred form, the core has a protective strip bonded to the exposed surface not covered by the cladding. 
     Preferably, the outer lateral surface has a drainage channel provided adjacent top surface of the core. 
     In accordance with a third aspect of the present invention there is disclosed a wall formed by a plurality of blocks as described above. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       An embodiment of the present invention will now be described with reference to the drawings in which: 
         FIG. 1  is a perspective view of a wall block of a preferred embodiments 
         FIG. 2  is a side elevation view of the wall block of  FIG. 1 , 
         FIG. 3  is a plan view of the wall block of  FIG. 1 , 
         FIG. 4  is an end elevation view of the block of  FIG. 1 , 
         FIG. 5  is a cross sectional view of a sealing strip used in the vertical joints of two adjacent blocks, 
         FIG. 6  is an exploded cross sectional view of a wall being constructed of the blocks of  FIG. 1 , 
         FIG. 7  is a partial plan view of a wall constructed of blocks of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     As illustrated in the drawings, a high insulation block  10  for building walls and the like includes a substantially rectangular, substantially rigid core  11  made from polyurethane foam with cement cladding  12  bonded to the core  11  on the lateral surfaces. The cladding  12  is offset and extends below the lower lateral surfaces aid is able to mate with the cladding  12  on the lower course of blocks  10  as the upper portion of the lateral surfaces of the cote  11  are not covered by the cladding  12 . This portion has a protective strip  13  bonded thereto, the strip preferably being made from galvanized steel. This strip is there to provide protection to the joints from fire and other problems. 
     The core  11  has a centrally located slotted groove or void  14  in the lower surface of the core  11 . The slotted groove  14  extends along the length of the core  11 , Furthermore, the core  11  has a frusto-conical vertically extending void  15  through the core  11 . This void  15  is centrally located within the core  11  whilst two semi frusto-conical voids or grooves  16  are located at the end surfaces of the core  11 . These grooves  16  form a frusto-conical void when two blocks  10  are placed adjacent each other. It is noted that due to the alignment of the blocks when building a wall, the vertically aligned voids extend from the top to the bottom of the wall. 
     The blocks  10  also have mating location lugs and recesses  17  and  18  located on the top and bottom surfaces of the core  11 , respectively. These lugs are preferably frusto-conical in shape and are used to have the correct alignment of the courses of the blocks  10  to ensure the vertically aligned voids as described above axe correctly formed. 
     The blocks  10  also have a drainage channel  19  formed at the upper portion left exposed from the cladding  12 . This drainage channel  19  is preferably located on the external surface of the block  10 . 
     The blocks  11  also have recesses  21  formed in the vertical edges of the core  11 . The recesses  21  are formed behind the cladding  12  and when adjacent blocks  10  are abutting, the recesses  21  are adapted to receive elongated vertical joint seals  22  which are spring fitted into the recesses  21 . These seals  22  are preferably pressed and folded from steel sheet material with drainage channels  23  formed therein. 
     The blocks  10  as described above are used to construct a wall  30  as seen in  FIG. 5 . The blocks  10  are formed into course on a floor structure  31 . The lowest, course is formed onto a course of starter blocks  32  whereby the cladding  12  overhangs the staffer blocks  32 . Naturally this a a preferred arrangement and other alternatives are used whereby die cladding may be removed from lowest course, the cladding can overhang or fit into slots in floor structure  31 , the floor structure  31  can have a elongated ridge formed therein to replace the starter blocks  32  and the like. 
     Notwithstanding the above, courses of blocks  10  are formed with the location lugs  17  and recesses  18  mating to align e blocks  10  correctly. Threaded rock  33  are positioned in the verticality aligned voids and are used with a nut  34  to compress the blocks as well as tying the blocks  10  to the floor structure. The horizontal and vertical voids are used as passageways for services such as electrical and plumbing services. The horizontal voids formed along the length of the blocks  10  provide for lintels over doors and windows as well as for services as described above. 
     The seats  22  inserted into the recesses  21  provide effective water sealing to the vertical joints with the drainage channels  23  located in the seals  22  allowing water to drain away, whilst tie overhanging cladding  12  and its compression applied by the treaded rod provides the water sealing to the horizontal joints. If there is any penetration of water the drainage channel  19  allows it to drain away and out from the lower horizontal joint. 
     It is seen that a wall  30  erected from the blocks  11  as described above with internal and external cladding is a load bearing structure, has efficient insulation properties and maintains water and wind exclusion. A bead of non setting mastic is applied between the horizontal and vertical faces as they contact adjacent blocks to act as a draft seal. The wall  30  does not require adhesive between the wall blocks due to the compression applied to the blocks by the treaded rods, accordingly the onsite construction time is minimized and construction costs are reduced. 
     As seen in  FIG. 7 , blocks  10  of the course above are shown in dashes and are offset by the length of half a block  10 . The corner block  10  has only half cladding  12  on one of Its sides with additional cladding  12  added to one or both ends. The blocks  10  are shown in a wall  30  and an opening  31  for a door is shown. 
     The foregoing describes only one embodiment of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the present invention 
     The term “comprising” as used herein is used in the inclusive sense of “including” or “having” and not in the exclusive sense of “consisting only of”.