Patent Publication Number: US-2004040249-A1

Title: Spacer element for building blocks, construction unit comprising said element and method of spacing building blocks

Description:
FIELD OF THE INVENTION  
       [0001] The present invention relates to spacer elements for spacing adjacent building blocks from each other and especially, but not limited to, spacer elements for spacing vertically adjacent bricks in a construction unit.  
       BACKGROUND TO THE INVENTION  
       [0002] Bricklaying is a skilled job and, therefore, should not be attempted by unskilled people for any significant job. Bricklaying requires laying bricks accurately in order to provide a stable vertical structure. This results from accurately spacing subsequent layers of bricks evenly with mortar. Such constructions built by unskilled people may be unstable and dangerous. However, the cost to employ a skilled bricklayer can be expensive and, thereby, prohibitive to some people.  
       [0003] Spacer elements that space adjacent building blocks from one another are known. However, prior art spacer element have a rigid structure. In use, the spacer element spaces adjacent building blocks. These spacer element are inserted between adjacent building blocks whilst the mortar is wet and the construction unit is being built. However, one problem with these prior art spacer elements results from the fact that as the mortar dries the mortar contracts and accordingly, the space between adjacent building blocks attempts to decrease. This contraction causes cracks to appear in the mortar since the upper building block does not move downwardly as a result of the spacer element. Without spacer elements, the upper building block would move downwards as the mortar contracted in order to prevent cracks appearing.  
       [0004] Similarly, as the construction unit is built up vertically, the additional weight urges the building blocks together. Accordingly, prior art spacer elements are strong in order to withstand the force and to space the building blocks vertically as the wall is built up. This strength thereby encourages the formation of cracks as the mortar dries.  
       [0005] It is an aim of the present invention to overcome at least one problem associated with the prior art whether referred to herein or otherwise.  
       SUMMARY OF THE INVENTION  
       [0006] According to a first aspect of the present invention there is provided a spacer element for spacing adjacent building blocks, the spacer element comprising a first engagement portion for engaging with a first building block and a second engagement portion for engaging with a second building block, the spacer element further comprising spacer means for spacing the first building block from the second building block wherein the spacer means is arranged to space the first building block from the second building block by a distance which reduces as a result of pressure applied to the spacer means.  
       [0007] The spacer means may comprise resilient means and preferably comprises a resilient structure. At least a part of the spacer means may fracture as a result of the pressure applied.  
       [0008] The spacer means may comprise flexible means and preferably comprise a flexible structure.  
       [0009] Preferably the spacer element comprises a longitudinal body. The longitudinal body may comprise the first engagement portion at one end thereof and may comprise the second engagement portion at the other end thereof.  
       [0010] The cross-section of the first engagement portion may be substantially “X” shaped. The cross-section of the second engagement portion may be substantially “X” shaped. The first engagement portion may comprise a tapered tip. The second engagement portion may comprise a tapered tip.  
       [0011] The spacer element may comprise at least one laterally extending arm and preferably comprises two laterally extending arms. Preferably the or each laterally extending arm is substantially planar. Preferably the or each laterally extending arm projects laterally outwardly from the longitudinal body of the spacer element and preferably from a position between the first engagement portion and the second engagement portion.  
       [0012] Preferably the first engagement portion has a greater longitudinal length relative to the second engagement portion.  
       [0013] Preferably the spacer means is located on the or each laterally extending arm.  
       [0014] The first engagement portion may comprise a tapered tip. The second engagement portion may comprise a tapered tip.  
       [0015] The spacer element may comprise at least one laterally extending arm and preferably comprises two laterally extending arms. Preferably the or each laterally extending arm is substantially planar. Preferably the or each laterally extending arm projects laterally outwardly from the longitudinal. body of the spacer element and preferably from a position between the first engagement portion and the second engagement portion.  
       [0016] Preferably the first engagement portion has a greater longitudinal length relative to the second engagement portion.  
       [0017] Preferably the spacer means comprises two spacer members. Accordingly, one spacer member is on one laterally extending arm and a second spacer member is on a second laterally extending arm. Preferably the or each spacer member comprises a generally planar member. Preferably the or each spacer member is arranged, in use, to be generally vertical. Preferably the or each spacer member is orientated in a plane substantially parallel to the longitudinal plane of the longitudinal body of the spacer element.  
       [0018] Preferably the or each spacer member comprises a tapered body and preferably a downwardly tapered body. The outer face of the or each spacer member may be substantially vertical. Preferably the inner face of the or each spacer member is angled downwardly and outwardly.  
       [0019] Preferably the top portion of the or each spacer member projects upwardly relative to the upper surface of the or each laterally extending arm, and preferably projects upwardly in. the region of 0.25 mm to 1 mm and preferably substantially 0.5 mm.  
       [0020] Preferably the lower edge of the or each spacer member extends downwardly relative to the lower surface of the or each laterally extending arm, and preferably extends downwardly in the region of 1 mm to 3 mm and preferably substantially 2 mm. Preferably the lower edge of the or each spacer member fracture as a result of pressure applied, in use.  
       [0021] Preferably the spacer means comprises at least one support member and preferably comprises two support members.  
       [0022] Preferably the or each support member extends to a tip which provides a contact surface to contact the second building block.  
       [0023] Preferably the or each support member projects outwardly from the or each spacer member.  
       [0024] Preferably the or each support member projects upwardly relative to the or each laterally extending arm. Preferably the or each support member projects upwardly to a support tip.  
       [0025] Preferably the or each support member is flexible.  
       [0026] Preferably the or each support member is able to pivot or flex as a result of pressure applied from above, Preferably the or each support member is able to pivot or flex about the lower edge of the or each spacer member.  
       [0027] Preferably at least a part of the lower edge of the or each spacer member is arranged, in use, to fracture as a result of the pressure applied.  
       [0028] According to a second aspect of the present invention there is provided a construction unit comprising a plurality of building blocks whereby vertically adjacent building blocks are spaced from each other by a spacer element in accordance with the first aspect of the present invention.  
       [0029] Preferably the construction unit comprises a plurality of generally horizontal rows of building blocks. Preferably the building blocks in vertically adjacent rows are laterally offset relative to each other.  
       [0030] Preferably the upper surface of each building block engages with two spacer elements. Preferably the lower surface of each building block engages with two spacer elements.  
       [0031] According to a third aspect of the present invention there is provided a method of spacing building blocks comprising engaging a spacer element with a first building block and a second building block whereby the spacer element provides spacer means which spaces the first building block from the second building block by a distance which reduces as a result of pressure applied to the spacer means.  
       [0032] Preferably the method comprises applying pressure to the spacer means by supporting further building blocks on the second building block.  
       [0033] Preferably the method comprises distributing mortar between the first building block and the second building block. Preferably the method comprises applying pressure to the spacer means by allowing the mortar to set and, thereby, contract. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0034] The present invention will now be described, by way of example only, and with reference to the drawings that follow, in which;  
     [0035]FIG. 1 is a front view of a preferred embodiment of a spacer element.  
     [0036]FIG. 2 is a side view of a preferred embodiment of a spacer element.  
     [0037]FIG. 3 is a plan view of the top of a preferred embodiment of a spacer element.  
     [0038]FIG. 4 is a plan view of the bottom of a preferred embodiment of spacer element.  
     [0039]FIG. 5 is a side view of part of a preferred embodiment of a spacer element.  
     [0040]FIG. 6 is a cross-section through a part of a construction unit showing a preferred embodiment of a spacer element spacing vertically adjacent building blocks.  
     [0041]FIG. 7 is an exploded view of a part of a construction unit.  
     [0042]FIG. 8 is a side view of a construction unit.  
     [0043]FIG. 9 is a side view of part of a construction unit.  
     [0044]FIG. 10 is a plan view of a pert of a construction unit comprising a double walled structure.  
     [0045]FIG. 11 is a side view of a part of a construction unit comprising a double-walled structure.  
     [0046]FIG. 12 a  is a side view of a reconstituted stone building block.  
     [0047]FIG. 12 b  is an end view of a reconstituted stone building block.  
     [0048]FIG. 12 c  is a plan view of a reconstituted stone building block.  
     [0049]FIG. 13 is a side view of a construction unit comprising reconstituted stone building blocks.  
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
     [0050] A spacer element  10  comprises a first engagement portion  12  and a second engagement portion  14 , as shown in FIGS.  1 - 4 . The first engagement portion  12  or the lower engagement portion is arranged, in use, to engage and locate in a hole provided in an upper surface of a building block or brick. The second engagement portion or the upper engagement portion is arranged, in use, to engage and locate in a hole provided in a lower surface of a second building block or brick. The term building block is defined to cover all blocks suitable for building, for example bricks, stone blocks etc.  
     [0051] The first engagement portion  12  comprises perpendicular planar members which tape towards a tip  13  at the lower end thereof. The first engagement portion  12 , thereby has a substantially “X” shaped cross-section. In use, the first engagement portion  12  is inserted into a hole defined in a brick. The hole may have mortar located therein and/or located thereover. Accordingly, the cross-section of the first engagement portion  12  enables the first engagement portion to be easily inserted. If the cross-section of the first engagement portion  12  was substantially the same as the cross-section of the aperture, this would result in the first engagement portion  12  being difficult to insert as a result of the pressure being applied to the mortar which would be inhibited from flowing out of the hole. Similarly, the second engagement portion  14  is substantially “X” shaped in cross-section and tapers towards a tip  15  at the upper end thereof.  
     [0052] The spacer element  10  comprises two laterally extending arms  16 ,  18  which project outwardly from the spacer element  10  between the first engagement portion  12  and the second engagement portion  14 . The laterally extending arms  16 ,  18  are substantially perpendicular to the longitudinal body of the spacer element  10 . The laterally extending arms  16 ,  18  secure to spacer means in the form of spacer members  20 ,  22  which are thereby spaced from the longitudinal body of the spacer element  10 . The spacer members  20 ,  22  have downwardly extending tapered cross-sections, as shown in FIG. 5. The spacer member  20  comprises an upwardly projecting top portion  24  which projects above the upper surface of the respective laterally extending arm  16  by 0.5 mm. The outer face  26  of the spacer member  20  is substantially vertical whereas the inner face  28  the spacer member  20  is angled downwardly and outwardly relative to the longitudinal body of the spacer element  10 . The differences in these angled faced  26 ,  28  creates the overall tapered cross-section. The spacer member  20  comprises a lower edge  30  which extends below the lower. surface of the respective laterally extending arm  16  by 2 mm.  
     [0053] The spacer members  20 , 22  provide an upper contact surface to contact and support a brick located above and a lower contact surface to contact and support the spacer element  10  on a surface of a lower brick. The lower contact surface is provided by the lower edge of the spacer member  20 . Accordingly, the contact area will be relatively small. Mass produced bricks contain a proportion of granular products (for example glass or coal) in order to reduce the cost of the bricks. Such granules thereby appear on the surface and result in the upper and lower surfaces of the brick being uneven. Accordingly, when a spacer element is engaged thereon, if the contact surface of the spacer element contact a granule then the spacer element may project upwardly at an angle or may be loosely secured. This is especially apparent with prior art spacer elements which have a relatively large contact area, Therefore, since the present invention has a minimal contact area provided by the spacer members, the probability of contacting a granule is reduced. In addition, the spacer element  10  can be rotated, relative to the brick in order to prevent contact with an uneven surface or granule. Furthermore, the spacer members are constructed from a material which may develop a recess for a granule as pressure is applied and will thereby encourage an even and secure contact with both bricks.  
     [0054] The spacer element comprises two support members  32 ,  34 . The support members  32 ,  34  extend laterally outwardly from the respective spacer members  20 ,  22 . As shown in more detail in FIG. 5, the support member  34  extends laterally outwardly to a tip  36 . The support member  34  also tapers upwardly with respect to the laterally extending arms  16 .  
     [0055] The spacer element  10  has a set of recesses  40  provided in the connecting area between the first engagement portion  12  and the laterally extending arms  16 ,  18 . In use, the recesses  40  locate adjacent to the periphery of the hole in the brick into which the first engagement portion  12  is inserted. The holes provided in the bricks typically have burred edges at the surfaces of. the brick. Accordingly, the recesses  40  enable the first engagement portion  12  to be inserted into the hole and rotated once located therein. This prevents the spacer element  10  from abutting the burred edges which may encourage the spacer element  10  to be vertically angled rather than substantially vertical. The recesses  40  may be substantially circular or arcuate and be defined in the first engagement portion  12  and the laterally extending arms  16 ,  18 . Similarly, the second engagement portion  14  has a series of indentations  42  defined herein. The indentations  42  and provided in the second engagement portion only and accommodate any burrs projecting inwardly from the hole in the second brick.  
     [0056] As shown in FIG. 6, the first engagement portion  12  of a spacer element  10  locates in a hole  44  provided in a first brick  46 . The second engagement portion  14  locates in a hole  48  provided in a second brick  50  wherein the second brick is vertically adjacent to the first brick  46 . Similarly, a second spacer element  51  may vertically space the second brick from a vertically adjacent third brick  52 .  
     [0057] In building the construction unit or the wall the first layer of bricks is laid. Thereafter, mortar is located on the upper surface of the first layer and spacer elements  10  are pushed through the mortar and engage with the bricks through the first engagement portions  12  and the associated holes. The spacer elements thereby provide upwardly projecting second engagement portions  14  in order for the next level of bricks to be laid. The spacer elements  10  provide spacer means which space the next layer of bricks from the lower layer of bricks by a particular distance, The upper brick will first abut the tip  36 ,  38  of the support members  32 ,  34 . The support members  32 ,  34  may pivot or flex about the lower edges  30  of the spacer members  20 ,  22  and thereby reduces the spacing distance between the vertically adjacent bricks. As the wall is built vertically upwards further pressure will be placed on the support members  32 ,  34  and the spacer members  20 ,  22  which may cause the lower edges  30  of the spacer members  20 ,  22  to fracture or shear or crumple. This will further reduce the distance between the vertically adjacent bricks. As the pressure increases the spacer members  20 ,  22  deform and the stress in the spacer members  20 ,  22  increases over the elastic limit or yield point add will eventually fracture. The arrangement of the spacer members  20 ,  22  and the respective support members encourage the stress to increase in the lower edges of the spacer members  20 ,  22 . Since the outer faces of the spacer members  20 ,  22  are substantially vertical and the inner face of the spacer members  20 ,  22  are angled downwardly and outwardly, this arrangement encourages the lower edges of the spacer members  20 ,  22  to shear or crumple. The initial spacing distance of the spacing members may be 11 mm and, the final spacing distance of the spacing members, once pressure has been applied, may be 10 mm. Prior art spacer elements are initially provided with the final selected spacing distance, for example 10 mm but the mortar may contract to be less than this 10 mm space and thereby produces cracks in the mortar. If spacer elements are not used, then an unskilled person-may construct a wall having an incorrect height since allowance for the shrinkage may not have been made.  
     [0058] This reduction in spacing distance is advantageous since as the mortar sets, the mortar contracts. If the spacer element rigidly spaced the vertically adjacent bricks then the contraction of the mortar may cause cracks to appear in the mortar between the vertically adjacent bricks. Such cracks may enable fluid to penetrate into the construction unit and to thereby weaken the structure. Accordingly, with the present invention the spacing distance of the spacer element  10  reduces as the wall is built vertically upwards and/or as the mortar contracts. The mortar will still be load bearing and the spacer element will not support the significant proportion of the load. Prior art rigid spacer elements may support a significant proportion of the load once the mortar has set.  
     [0059] As show in FIG. 7, each black  60  preferably has at of the brick. Accordingly, two spacer elements  10  may be engaged in each brick  60 . The upper engaging portion  14  of the first spacer element  10  may engage with a first brick and the upper engaging portion  14  of a second spacer element  10  may engage with a second brick. Accordingly, the bricks in adjacent layers will be laterally offset from each other, as in conventional walls, in order to increase the stability in the wall.  
     [0060] In the construction unit or wall,  64  the spacer elements will be arranged in vertical planes  66  across the width of the wall  64 , as shown in FIG. 8. This results from each hole in each brick having an upper engagement portion from a first spacer element located therein and a lower engagement portion from a second spacer element located therein. Alternatively, the spacer elements  10  may be used to space bricks from each other when vertically adjacent bricks are not laterally offset to each other.  
     [0061] The upper engagement portion  14  is longitudinally smaller than the lower engagement portion, as shown in FIG. 9. This is advantageous when engaging a brick on to the upper engagement portion  14  since it prevents the end  72  of the upper brick  70  initially abutting the mortar  74  located an the laterally adjacent brick  76 . If the end  72  of the upper brick  70  initially abutted the mortar and was then moved downwardly, this would result in the mortar being moved downwardly relative to the brick  76 . This would weaken the bond between the bricks since the mortar would no longer be uniformly distributed. The same effect occurs if the mortar was to be placed on the lateral end of the upper brick  70 . Accordingly since the upper engagement portion  14  is reduced in height and comprises a tapered upper end this reduces the effect and maintains the mortar evenly distributed.  
     [0062] The spacer elements  10  may be used in wall or construction units comprising two or more leaves, as shown in FIG. 10 and FIG. 11.  
     [0063] The spacer elements are used as previously described. However, reinforcement members in the form of a wire tie-ins  80  are arranged to secure a spacer element  10  from a first leaf to an adjacent spacer element  10  in the second leaf. The wire tie-in  80  comprises a first loop  82  and a second loop  84 . The loops  82 ,  84  locate around the spacer elements  10 . The outer portion of the first loop  82  locates around a first spacer element  10  and the outer portion of the second loop  84  locates around a second spacer element  10 . The loops  82 ,  84  are secured to each other through a twisted connecting section  86 . Accordingly the distance between the outer portions of the first and second loops  82 ,  84 , and hence the overall length of the tie-in  80  many be reduced by twisting the connecting section  86  further. The wire fixings may secure around the recesses  40  provided in the spacer element  10 .  
     [0064] The spacer elements  10  may be used with a variety of different building blocks including reconstituted stone. blocks  90 , as shown in FIG. 12 a - 12   c  and FIG. 13. The reconstituted stone blocks  90  may have a slot  92  or engagement hole defined in an upper surface and in a lower spacer elements to be located and engaged the therein. As shown in FIG. 13 the reconstituted stone blocks may be of a variety of shapes and sizes.  
     [0065] The spacer elements may be used to construct a wall by simply locating the spacer element and building the wall without applying any mortar. Once complete the spacer members will have reduced in height to provide a natural separation between the rows. Mortar may then be applied between the rows through use of a tool, for example a gun mortar. The final appearance will be of a conventionally built wall. The mortar is preferably non-contracting mortar. Alternatively, an expanding grout material may be applied between the rows in order to give the appearance of a conventionally built wall. Such constructions are suitable for interior, non supporting walls.  
     [0066] The reader&#39;s attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.  
     [0067] All of the features disclosed in this specification (including any. accompanying claims, abstract and lo drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.  
     [0068] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.  
     [0069] The invention is not restricted to the details of the foregoing embodiments(s). The invention extend to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.