CONSTRUCTION OF BUILDINGS USING WOODEN BLOCKS
This is a concept for constructing a building entirely out of wood, the building being any house from A to Z, the ultimate objective being self-build. Once the blocks have been placed one on top of the other, and once the structure is finished, the house is complete! There is no longer any need to provide an inner or outer skin. Indeed, the inside of the blocks, the inside of the walls, can accommodate all possible and conceivable utility shafts, electric wiring, water supply pipes, heating pipes, waste pipes, ventilation and insulation . . . The design is not simply a block, that would be too easy, but a block of a certain size which, when applied in certain ways, enables an entire house or an entire building to be constructed quickly and simply. Thus:—the walls are built (without a single nail or screw, simply by nesting the blocks together, like a construction set);—floor beams are created using the same wooden system, but prestressed with threaded rods, providing very high strength and able to cover wide spans (the wall-floor relationship is a fundamental element justifying this type of build);—a staircase is created (again using the same system of blocks and simply by nesting them together) (a child's toy at a ridiculously low cost);—and a roof is built (the simplest and most economic form of roof would be a flat roof, but a sloping roof could also be created). Even though foundations are needed only at the corners of the main bearing walls, this
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System to build houses or buildings using wooden blocks. Building system from foundations to the roof, interlocking wooden blocks, requiring no nails, no screws. The basic wood block is the carrier.
The entire building is supported by beams that link the entire building.
BACKGROUND ARTThere are many patents in the field of wooden buildings, especially to build walls with wooden blocks.
WO 2008/129154 AI Building system to erect frames by mixed wood and metal.
WO 2009/027448 AI Prefabricated wood building system.
WO 92/21417 Building Blocks Set.
WO 97/39204 Building Module and building module System for producing flat construction, especially walls.
WO 2009/024651 AI Building block of wood or other material.
WO 91/08359 Construction element for building cabins
WO 00/01902 Modular stairway System, method for erecting stairway and kit thereof.
WO 93/14282 A method for the manufacture of prestressed wooden building blocks and resulting modules including architectural structures.
WO 2007/028658 AI Construction system for the construction of walls.
WO 2004/109028 AI Structural wood elements and building systems from these elements.
WO 88/05485 Construction system by modular wooden frame and their assembly process.
U.S. 005890332A Reconstituted wood block modular building system.
WO 2010/047570 AI A double walled wood block and a method for building a wall thereof.
WO 03/016645 AI Wall Construction.
Most of these systems use interesting blocks shapes to build walls. However these patents do not take all the problems related to construction into account, from the foundation to the roof. For example, the binding of walls and floors is rarely mentioned in most of these patents. But to be able to build several levels, the binding of the wall and the floor is a crucial issue.
In this patent, all the technical building problems are integrated: the foundation's erection and the junction between the foundations and the walls. The patent takes into account all the difficult situations that occur in construction and gives as well the possibility to incorporate a beam or a concrete belt to attach firmly all the walls and the foundations. It provides a solution to the intersection between two, three or four walls. The floors can be built at different levels. It also gives the possibility to create robust and sustainable constructions. It also deals with the issue of building a roof. The incorporating of door frames and windows is also managed, as well as the creation of a stair and the passage of ducts. It also allows the placement of a thick layer of insulation in the walls and floors.
This is a concept to build a wooden house or a wooden building, designed from the beginning to the end. The ultimate goal is a simple construction method. Once the blocks are mounted on each other, once the structure is completed, the house is finished! In most cases, it is not really necessary to build an internal or external finishing. Indeed, electrical wiring, heating pipes, water pipes and insulation are already placed inside the walls and the floors made of wooden blocks.
This is not simply a block, but it is a block of a fixed size and form. If the blocks are fixed in each other in the right way, one can quickly and simply build a building.
The walls are constructed without nails or screws, but just by simple fitting. Doors and windows are easily inserted. In the same way, with the blocks, one can create stairs. The installation of the stairs is simple and cheap, however they are comely and of great resistance, built with the same system used to build the walls. The junction of the wall and the floor is a key element to ensure the stability of the building. The same junction can be applied between the wall and the roof. Building a flat roof would be the most easy and economical way. But various types of roofs are possible. Although foundations are only necessary at the corners of the main load-bearing walls, this light construction is very solid. The joists distribute the weight of the whole construction on the several walls. Vertical threaded rods start in the foundation till the roof. The weight returns to the foundation. The whole structure is firmly attached to its foundations. The building can withstand harsh winds and climates.
DISCLOSURE OF THE INVENTION Technical ProblemLike in Roman times the construction process is still mainly done on the building place. The goal of this patent isn't just to create a wooden block. The biggest challenge was to solve the issue of binding the walls between them, and especially to connect the walls to the floor, and still have a robust and stable construction. As well as allowing the passage of ducts for the electric, water pipes, heating pipes and sanitary evacuations, and allowing a thick insulation layer to reduce energy needs. In traditional houses, once the main building structure is built only half of the work is done. In traditional houses, it's still necessary to hide all ducts and inside, it's necessary to place a finishing. The construction of a classic home requires a lot of money and time to place all these successive finishing. It is often necessary to build three successive structures, the carrying structure, the inner finishing (to hide technical networks), and finally an outer insulation. All of these operations are very expensive and take a huge amount of time.
Technical SolutionWith the construction of buildings using wooden blocks, a single structure, and a single operation is enough. The wooden blocks fixed in each other play the role of the carrying wall. The pipes and insulation are directly inserted inside the wooden blocks. It would only be for aesthetic purposes or to protect more the main structure that one could add layers on the blocks. Therefore, the wooden blocks greatly reduce the building time and costs. The construction of a building with wooden blocks doesn't rely on any professional knowledge, and one could for example easily build his own home. The only knowledge would be the same, as a child when it plays with construction toys.
Advantageous EffectsBuilding with wooden blocks is fast and easy. No nails or screws are necessary. The wooden blocks fit together. Any tinker can build his house in a record time, saving time and money. Once the structure is completed, the ducts and the insulation can easily be placed. This simple construction system using just wooden blocks would give the possibility to everyone to have access to quality homes without ruining them financially.
The description (*). (*) To help the reader, each element created, each unit created, each building system created, was designated by a Roman numeral. These Roman numerals can be found in the description in Fig. drawings and original claims. For all elements created, a hierarchy was established in italics denotes the planks created. In italics and bold denotes the blocks created, using several combinations of planks. And finally, in italics, bold and underlined, the created building systems are meant, which are composed of different blocks and different elements. We adopted the same hierarchy as in the original claims. As an indication, some dimensions are given in the form of a multiple of X such (X*I) or (X*2) and so on. Indeed, the combination of the different dimensions plays an essential role in the assembly of the building, which follows a well-defined frame dimensions.
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The corner block (VI). The corner block is the result of crossing two planks (IV) and two planks (V). The square of wood (VII) fits into the corner block to reinforce it. Its dimensions are the internal dimensions of the corner block. In the length [(X*2)−(2*E)], in the width [(X*2)−(2*E)] and its height is the half of the height of a block (X*0.5). “E” is the thickness of the wood.
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Concrete foundations are needed in the corners of the walls which will support the whole load of the construction. To cast the concrete foundations, it's necessary to pile formworks (VIII) using the corner blocks (VI), each one above the other. This will form the formwork for the concrete. The corner blocks buried in the ground will receive a tar coating. Through the holes (7), reinforcing bars or threaded rods can be introduces (11) which will form reinforcing steel inside the formwork. Four vertical reinforcing bars slide over the entire height of the formwork (13). In the formwork's centre, a long reinforcing bar or a cable slides vertically (14). It binds the walls, the roof and the foundation. This reinforcing bar (14) must penetrate deeply into the concrete and come out after the height of one or more floors. The reinforcing bar or cable (14) is then extended to the roof. It binds firmly the whole construction and the concrete foundations. If necessary, one can construct concrete columns on the same principle.
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Creating a flat roof begins with the placement of floor beams (XXXVIII) and a traditional floor construction (31). Then, on the floor, a classic roof is constructed: a steam barrier (32) is placed and a fire-retardant insulation in height (X*3) (33). Thus, with insulation in the walls (X*2) and an insulator (X*3) roof and under the first floor, the building with have a low energy consumption. The upper face of the insulator has a small slope with relative to the horizontal so that the water flows towards the gutter (36). It is covered with a waterproof material, a copper, zinc, steel plates, or tar, etc. (34). The gutter could be housed in the last stack of block wall (35). The last stack of blocks is composed of basic blocks which have a cut on the top half of the intermediate plank (XIII). In this half-height block left free, a gutter can be inserted. The drain hose may be inserted in the middle of the ledge and goes down inside the wall (36). On the same principle, oblique roofs can be maid.
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Again, the elongated corner blocks are almost identical to corner blocks, they follow the same characteristics, the same frame, the same male and female ends tabs (1) and (2) the same cuts directing up and down . . .
Thus, the elongated edge blocks and formwork blocks with elongated corner perfectly fit into each other.
The only difference is that no dovetails are used but holes to receive the threaded rod horizontally, which is bolted at both ends.
We start by creating: Plate block elongated wedge shuttering, notches downwardly situated side mortise (2).
(LXIX) Plate block elongated wedge shuttering, notches downwardly situated tongue side (1) (LXX) Plate block elongated wedge shuttering, cuts down mortise cut end (LXXI); Plate block elongated wedge shuttering, cuts down tab cut end (LXXII).
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The next stairs and the following will only (X*1.28) in height. In fact, as the second stair fits into the first stair (51), the thickness of the external planks does not count. The length of each stair is (X*2). Two basic stair blocks (III) (52) are inserted to obtain one step length.
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The ultimate goal of the creation is to give the ability to a non-professional to easily build his own home. We propose a concept from A to Z to build a house or other building. Thus, in the factory, we will trim twenty five different planks. Then, in the workshop, with the combination of these twenty five planks we will get our forty three different blocks, needed for the construction. Finally, on the building site, according to the plans and instructions, 18 different mounting systems could be used to obtain a home or a strong and durable building.
MODE FOR INVENTIONThe invention has required several years of research, development and tests before coming to a complete construction concept with blocks of wood, from the foundation to the roof. This is not just inventing a block, but it is a complete concept of construction of a building that is being sought. And this construction is done by simply interlocking wooden elements, without any nail, from foundation to roof.
INDUSTRIAL APPLICABILITYIn the factory, twenty five planks of different shapes must be cut.
In the workshop, with the combination of the twenty five pre-cut wooden planks, by simple fitting, forty three different wooden blocks can be crafted.
Sequence Text List
Claims
1. Device to realise buildings using wood blocks; It is characterized in that it comprises a first member, the base block consisting of wooden planks; Two planks called one external and the other internal; The cutting of the two planks is identical; In the axis of the plank thickness, the top has a languet (5), the underneath is grooved (6), a vertical side has a languet (1) and the other vertical side is grooved (2); The top of the plank is bevelled on one side thereof for discharging the drop of water (9); As the internal plank rotates 180 degrees to the external plank, therefore, the vertical end of the external corner left of the block has a languet (1); The vertical end of the left inside corner of the block is grooved (2); Therefore, the vertical end of the right outside of the block is grooved (2); Consequently, the vertical end of the internal right side of the block has a languet (1); By slotting the blocks following their length, the two sides of the block preceding or following will fit; If the block rotates 180 degrees, the block fits also with the preceding and following blocks; Four intermediate planks attach the external and internal planks; The intermediate planks are perpendicularly located between the external plank and the internal plank; The vertical ends of the intermediate planks being secured to the external and internal planks by interlocking dovetail (3) (4); In the axis of the intermediate plank thickness, the top has a languet (5), the underneath is grooved (6); Small holes (7) made in the intermediate planks allow threading of the threaded rods (11) horizontally from one end to the other end of the wall; The threaded rods are bolted (12) at the ends, providing a belt effect and binding all the blocks well together; A large hole (8) in the centre of the intermediate planks, diverse ducts can run horizontally inside the block; An insulating layer can be put in the free spaces left inside the blocks; All the dimensions of the block in height, in length and width being multiples or submultiples of (X), the positioning of the intermediate planks inside the blocks also being multiples or submultiples of (X); All the dimensions of the various devices which are necessary in the construction of buildings using wooden blocks being also multiples or submultiples of (X).
2. Device according to claim 1 characterized in that a corner block ensures the junction between perpendicular walls; Its base is in shape of a square, its height and sides are equal to the basic blocks width, it is composed of four planks of same height as the basic block; two of these planks have two notches facing downwards (9) and the two other planks have notches facing upwards (10); the notches allow an interlocking of these four planks, which will together form the corner block;
- Beyond the notches the rest of the plank is a sub-multiple (X); Like the basic block, in the axis of the plank thickness of the corner block, the top has a languet (5), underneath it is grooved (6), a vertical side has a languet (1) and the other vertical side is grooved (2); Like the basic block each side of the corner block has a plank bit, which has a languet and another which is notched, allowing to the corner block to form an interlocking with any other block, even if it is rotated of 90 or 180 degrees; The four small holes (7) in each plank allow the threading of threaded rods horizontally (11) going from one end to the other of the wall; The threaded rods are bolted at the both ends of the wall (12) which creates a waist beam between the walls and corners, reinforcing the whole structure; A wooden square piece could slip into the interior of the corner block to solidify, while the bolts (12) are being clamped; The square wooden piece, in addition to the small horizontal holes (7) has in its centre a large vertical hole (16) allowing the passage of a threaded rod, or a cable or a rebar (14) attached vertically from the foundation to the roof and consequently binding firmly the whole construction. The vertical hole in the centre (16) could also let pass several vertical technical ducts; The corner blocks fixed one on top of the other could become wooden columns, in case there is need to raise the construction; The corner blocks posed one on top of the other become a wasted formwork, in which horizontal rebars (11) could be inserted through the small holes (7), vertical rebars (13) (14) and the concrete; this system serving as a wasted formwork to make a concrete column or foundation.
3. Device according to any one of the preceding claims characterized in that an elongated corner block would provide a better connection between a corner and the walls; An external plank and an internal plank where at intervals multiple of (X), beginning with two dovetail notches (4) of the same height as the plank height; In which slip the dovetail heads (3) of two intermediate planks; and continuing with two upward notches (10) in which fit the two grooves facing downwards (9) of two corner block planks; Consequently, the elongated corner block is a corner block prolonged by the half of a basic block; The elongated corner block ensures a perfect cohesion between the corner and the wall; If the elongated portion of the elongated corner block is inserted into a wall, in the next stack of blocks, the elongated portion can be rotated of 90 degrees to fit into the perpendicular wall, and so on, ensuring a perfect cohesion of the corner and of two, three or four walls ending in the corner; The positioning of the external and internal planks and of the intermediate planks of the elongated corner block also has the measures of multiples of (X); If there is need, a basic block could perfectly fit (17) on an elongated corner block or inversely.
4. Device according to any one of the preceding claims characterized in that the beams placed horizontally inside the wooden blocks maintain the building; The beams shift the loads to the corners and to the foundations; Foundations being therefore required only under the corners of the walls; The horizontal beams act as a guide and a base for the placement of the first stack of blocks at the base of the walls; The horizontal beams are used to place the base of potential floors; The horizontal beam supports all the loads at the base of the walls, at the base of the floors, at the top of the walls, at the top of the building, at the base of the roof, at the base of the gutter; To make an opening in the wall, the beam is used as a lintel or a threshold on the top of a door or a window; At the ends of the horizontal beams which start and end at the corners of walls, vertical holes (7) allow the passage of rebars, or cables or threaded rods (14); The rebar ascends vertically from the foundation and joins the roof, passing inside the corners of the walls; The beams bolted at the rebar (14) bind the entire construction and allocate all charges in the foundations located underneath the corners of the walls; Large holes made along the axis of the horizontal beams allow the passage of vertical technical ducts (28); The vertical technical ducts and the horizontal beams are hidden inside the blocks of the walls; The lower half or upper half of the intermediate planks of the blocks is cut (18) (19) to leave the necessary space to pass a horizontal beam; Two beams intersect in a corner of two walls by cutting the lower half of the intermediate planks (19) of the stack of the blocks which enclose the beam in a first wall, and by cutting the upper half of the intermediate planks (18) of the stack of the blocks which enclose the beam in the second perpendicular wall; The crossing of these two horizontal beams in the corners of the walls requires to carve the corner blocks (20) (21) and the elongated corner blocks (20) (21); to deal with all the situations of two beams intersected in a corner where could join two walls or three or four walls; A square wooden piece (22), with a vertical hole in the centre allowing the passage of any vertical ducts, is inserted in the corner block or in the elongated corner block; indeed, the square wooden block strengthens the blocks weakened by cuts.
5. Device according to any one of the preceding claims characterized in that the floor beams could be made following the same principle as the basic block; The length of a beam and the external and internal planks would be of corresponding to length of the range of the coverage area and its two supports (23), all the dimensions remain multiples and submultiples of (X); The floor beams are elongated basic blocks, rotated of 90 degrees on themselves; The external and internal planks end above and under the floor beam; Thus the bottom plank overtakes the tensile forces, at the same time the top plank overtakes the compression forces while the intermediate planks overtakes the shear forces; Several square wooden pieces are inserted into the free spaces to reinforce the floor beam; A large hole (16) at the centre of the square wooden pieces reduces their weight and allows the horizontal passage of technical ducts hidden inside the floors; Several threaded rods (11) threaded along the length of the floor beam and bolted at both ends multiplies the flexural strength of the floor beams allowing large ranges; The placement of the very light floor beam (24) doesn't require lifting equipment, the square wooden pieces and the threaded rods can be inserted once the floor beam is put into place; The floor beam can be a vertical, horizontal or inclined structural member in the construction of buildings industrial and others.
6. Device according to any one of the preceding claims characterized in that the support of the floor beams on the wall requires to cut the blocks in one or more stacks of blocks in the goal to place the floor beams on the wall; Four shapes of basic blocks cut to place the floor and two shapes elongated corner blocks cut to insert the floor beams, allowing to fore say all possibilities; The size of the cuts in the blocks equals the section of the floor beams; Besides the floor beams are distributed according to a multiple of (X) along the last stack of blocks of the bearing walls; Several wall hooks (27) inserted vertically in the small holes (7) of the intermediate planks could tie together several piles of superposed blocks weakened by cuts; In these blocks cut to allow the passage of floor beams, large circular holes allow the passage of technical ducts (28) to connect vertical ducts running through the walls and horizontal ducts running through the floors; Inside the blocks of the wall, a horizontal beam, inserted underneath the supports of the floor beams, a horizontal beam returns the weight of the floors to the corners of the walls and then into the foundations; The first horizontal beam located under the supports of the floor beams is reinforced by a second beam placed directly on the support of the floor beams; The second beam being connected at the first beam by one or more vertical threaded rods (29) conferring a high resistance; Furthermore, this second beam will guide and support for any stack of blocks, which will build an upper level or a roof; The remaining voids in the walls are filled with insulating material (30).
7. Device according to any one of the preceding claims characterized in that a flat roof could be constructed like a floor; Once the floor beams are positioned, a traditional floor can be placed (31); The next step is to place a layer of insulating material (32); After a first sealing layer is installed (33); On the last stack of blocks, a beam, attached at the lower beams with threaded rods, can overtake the role of a waist beam (29) the threaded rods are attached (38) to the foundation through the rebar (14) located in the wall corners; The rebar ascends from the foundation to the roof; Finally a last sealing layer (34) covers the top of the walls; On the top of the wall, which is inserted into the final stack of blocks from which the upper half of the intermediate planks are cut (18), a gutter is inserted (35) to collect rain water; The discharge rainwater falls vertically in a duct located inside the wall (36).
8. Device according to any one of the preceding claims characterized in that the beams (37) can be inserted vertically in the plank ends emerging from the corners of the walls or columns, in order to strengthen the corners of the walls and columns, supporting thereby all loads of the construction; Such reinforcement is made with several vertical beams attached and bolted (29), through the horizontal threaded rods (11) which surround the building.
9. Device according to any one of the preceding claims characterized in that, for the construction of buildings located in regions with climate threats; A structure of concrete columns, and beam belts of concrete, can be made using the wooden blocks; In this case, the wooden blocks will serve as permanent formwork; If two, three or four concrete beams intersect at the concrete column, the corner blocks would require many cuts giving five different shapes of cut corner blocks used as formwork; In order to maintain a continuity between concrete beam belts and concrete columns, the intermediate planks of the basic blocks are replaced with threaded rods; The threaded rods act as a reinforcement inside the concrete while maintaining in place the planks serving as outer and inner formwork; Vertical reinforcements (29) and ducts (40) are slid into the formwork beams; Reinforcing the horizontal and vertical formwork beams and also closing the bottom of the formwork beam; The concrete remaining hidden inside the formwork, viewed from outside the construction looks as if it was completely made of wood; Indeed, the formworks stays in place; Once the concrete is poured, the rest of the construction can be built just using wooden blocks, which fit onto the wooden blocks used as formwork; Indeed, the basic wooden blocks fit into the formwork made of wooden blocks; Indeed, all the wooden blocks including the blocks used as formwork, follow the same principles of horizontal and vertical interlocking, the same principles of tenons and mortises, and the same proportions of dimensions of (X).
10. Device according to any one of the preceding claims characterized in that the floor beams can be used as structural elements to construct an oblique roof; At the base of the roof, several triangular joists (41) (43) maintain the oblique roof beams; Threaded through the beams holes (16), a round beam (42) maintains the oblique beams of the roof together; An insulator (44) and a traditional roof (45) is placed on this structure.
11. Device according to any one of the preceding claims characterized in that openings, doors and windows can be made inside the walls of the building, which are composed of wooden blocks; Along the door frame or window frame (46), the ends of the wooden planks are fixed; Thereby, door or window frames can fit in the opening; A wooden piece (49) which fills the remaining space is sufficient to clamp the frame against the wood languet of the block to hold it in place; To reinforce the construction, each stack of block is shifted of a half block; Half the length of a basic block (48) is necessary to fill the void, remaining along the openings; A horizontal beam which is inserted in the blocks can be used as lintel (38) and a piece of horizontal joist can be used as threshold (50).
12. Device according to any one of the preceding claims characterized in that two coupled basic blocks rotated of 90 degrees (52) to each other can form a stairway; by interlocking their upper plank to the bottom plank of another step (51); If this procedure is repeated, a stair takes shape; The intermediate planks of the stair blocks are proportioned to obtain a good proportion between the step height and the space available for the foot; Joists (56), horizontal threaded rods (53) and vertical threaded rods maintain the steps between them; The vertical threaded rods (54) can be used as long staircase guardrails; The staircase can take different shapes: straight, angled, parallel; The combination of beams (56), threaded rods (53) (54) and steps (58) allow to create various types of staircases using wooden blocks.
Type: Application
Filed: Jul 8, 2010
Publication Date: May 2, 2013
Applicant: (Rameldange)
Inventor: Vincent Lepot (Rameldange)
Application Number: 13/808,593
International Classification: E04C 2/30 (20060101);