BLOCK FOR USE IN AUTOMATED BUILDING CONSTRUCTION

Abstract

A block for automated building construction has a cuboid body including an opposed top and bottom, a pair of opposed ends, and a pair of opposed sides. The block is dividable lengthwise into block portions. Between each pair of adjacent block portions is a dividing slot(s) extending between the top and the bottom and transversely across the block, the dividing slot(s) separated from the opposed sides or an adjacent dividing slot by slender webs which bridge and connect the adjacent block portions. Each block portion includes holes extending between the top and the bottom. The holes include a larger hole, and smaller holes spaced apart around the larger hole. Each portion at opposing ends of the block includes a protruding tongue extending between the top and the bottom of the block, which is transversely offset with respect to a protruding tongue at the opposite end of the block.

Claims

1. A block for automated building construction, said block comprising a cuboid body including an opposed top and a bottom, a pair of opposed ends, and a pair of opposed sides; the block dividable lengthwise into a plurality of block portions, one or more dividing slots between each pair of adjacent block portions extending between the top and the bottom and transversely across the block, each of the one or more dividing slots being separated from the opposed sides or an adjacent dividing slot by slender webs which bridge and connect the adjacent block portions; each of the block portions including a plurality of holes extending between the top and the bottom thereof, where the plurality of holes comprises one or more larger holes, and a plurality of smaller holes spaced apart around the one or more larger holes; and wherein each of the end portions at opposing ends of the block comprises one or more protruding tongues extending between the top and the bottom of the block, each of the one or more protruding tongues is transversely offset with respect to the one or more protruding tongues at the opposite end of the block.

2. The block of claim 1, wherein each of the one or more protruding tongues at one end of the block are rotationally symmetrical to the one or more protruding tongues at the opposite end of the block.

3. The block of claim 1, wherein each of the end portions at opposing ends of the block comprises a pair of transversely spaced protruding tongues extending between the top and the bottom of the block.

4. The block of claim 1, wherein each of the one or more larger holes is positioned on a centreline of the block portion.

5. The block of claim 1, wherein each of the one or more larger holes is substantially square.

6. The block of claim 1, wherein each of a plurality of the smaller holes is elongate.

7. The block of claim 1, wherein each of a plurality of the smaller holes is a slot.

8. The block of claim 7, wherein at least one slot extends parallel to each side and end edge of each block portion.

9. The block of claim 8, wherein where two or more slots extend parallel to a side or end of the block portion, wherein the two or more slots extending parallel to a side or end of the block portion are aligned lengthwise.

10. The block of claim 1, wherein where two or more of the dividing slots are located between a pair of adjacent block portions, the two or more dividing slots between a pair of adjacent block portions are aligned lengthwise in a direction extending transversely across the block, and separated by one or more of the connecting slender webs.

11. The block of claim 1, wherein each of the block portions comprises a pair of larger holes spaced apart transversely across the block portion.

12. The block of claim 11, comprising one of: a length of approximately 490 mm; a width of approximately 190 mm; and, a height of approximately 250 mm, a length of approximately 600 mm; a width of approximately 190 mm; and, a height of approximately 400 mm, a length of approximately 600 mm; a width of approximately 290 mm; and a height of approximately 400 mm.

13. The block of claim 1, wherein each of the block portions comprises a single larger hole positioned at or proximate a geometric centre of a top of the block portion.

14. The block of claim 13, comprising one of: a length of approximately 500 mm; a width of approximately 90 mm; and, a height of approximately 250 mm, a length of approximately 600 mm; a width of approximately 90 mm; and, a height of approximately 400 mm.

15. The block of claim 1, wherein the block is made of clay.

16. The block of claim 1, wherein each of the tongues comprises a flat surface extending parallel to the surface of the end of the block, and sloping ramp surfaces extending on either side down from the flat surface to the surface of the end of the block.

17. The block of claim 1, wherein each of the protruding tongues protrudes approximately 5 mm from an end of the block.

18. The block of claim 1, wherein the pair of opposed sides comprise a plurality of grooves that extend between the top and bottom of the block and are spaced equidistant between the ends.

19. The block of claim 1, wherein the pair of opposed sides comprises a plurality of grooves that extend between the top and bottom of the block, wherein for each block portion a pair of grooves are separated by a smooth flat side portion that is aligned with and has a width substantially the same as a width of the one or more larger holes.

20. A block for automated building construction, the block for use in constructing an internal wall of a building, said block comprising a cuboid body including an opposed top and a bottom, a pair of opposed ends, and a pair of opposed sides; the block dividable lengthwise into a plurality of block portions, where between each pair of adjacent block portions there is at least one dividing slot extending between the top and the bottom and transversely across the block, the at least one dividing slot being separated from the opposed sides or an adjacent dividing slot by slender webs which bridge and connect the adjacent block portions; each of the block portions including a plurality of holes extending between the top and the bottom thereof, wherein the plurality of holes comprises one larger hole positioned at or near a geometric centre of a top of the block portion, and a plurality of smaller holes spaced apart around the larger hole; and wherein each of the end portions at opposing ends of the block comprises at least one protruding tongue extending between the top and the bottom of the block, the at least one protruding tongue is transversely offset with respect to the at least one protruding tongue at the opposite end of the block.

21. A block for automated building construction, the block for use in constructing an external wall of a building, the block comprising a cuboid body including an opposed top and a bottom, a pair of opposed ends, and a pair of opposed sides; the block dividable lengthwise into a plurality of block portions, where between each pair of adjacent block portions there is at least one dividing slot extending between the top and the bottom and transversely across the block, the at least one dividing slot separated from the opposed sides or an adjacent dividing slot by slender webs which bridge and connect the adjacent block portions; each of the block portions including a plurality of holes extending between the top and the bottom thereof, wherein the plurality of holes comprises a pair of larger holes spaced apart transversely across the block portion, and a plurality of smaller holes spaced apart around and between the larger holes; and wherein each of the end portions at opposing ends of the block comprises at least one protruding tongue extending between the top and the bottom of the block, the at least one protruding tongue is transversely offset with respect to the at least one protruding tongue at the opposite end of the block.

22. A wall assembly comprised of a plurality of blocks as in claim 1, wherein the blocks are laid in a plurality of courses, and an adhesive is applied between each course of blocks and a successive course to bond the courses of blocks.

23. A wall assembly comprised of one or more internal walls constructed using the blocks of internal wall block of claim 20 and one or more external walls constructed using blocks of an external wall block, wherein the blocks are laid in a plurality of courses, and an adhesive is applied between each course of blocks and a successive course to bond the courses of blocks.

24. The wall assembly of claim 22, wherein the adhesive is machine applied to the base of a block before the block is laid onto a lower course.

25. The wall assembly of claim 22, wherein at least two parallel beads of adhesive are applied onto the base of a block along a lengthwise extent thereof.

26. The wall assembly of claim 22, wherein the adhesive is further applied onto one or more end faces of a block to form a perp joint with an adjacent block in a course.

27. The wall assembly of claim 23, wherein internal walls are tied into external walls by inserting internal wall blocks between adjacent external wall blocks for at least alternating courses of blocks so that ends of the internal wall lay flush with an outer face of an external wall.

28. The wall assembly of claim 27, wherein each of the larger holes in an external wall block or block portion aligns with a corresponding larger hole in an internal wall block or block portion when one is stacked atop of the other.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0055] Forms of the present disclosure will be discussed with reference to the accompanying drawings wherein:

[0056] FIG. 1 is an upper isometric view of a block according to a first form;

[0057] FIG. 2 is a top plan view of the block of FIG. 1;

[0058] FIG. 3 is a right side plan view of the block of FIG. 1;

[0059] FIG. 4 is an end view of the block of FIG. 1;

[0060] FIG. 5 is a bottom plan view of the block of FIG. 1;

[0061] FIG. 6 is a left side plan view of the block of FIG. 1;

[0062] FIG. 7 is an end view of the block of FIG. 1;

[0063] FIG. 8 is a lower isometric view of the block of FIG. 1;

[0064] FIG. 9 is an upper isometric view of a block according to a second form;

[0065] FIG. 10 is a top plan view of the block of FIG. 9;

[0066] FIG. 11 is a right side plan view of the block of FIG. 9;

[0067] FIG. 12 is an end view of the block of FIG. 9;

[0068] FIG. 13 is a bottom plan view of the block of FIG. 9;

[0069] FIG. 14 is a left side plan view of the block of FIG. 9;

[0070] FIG. 15 is an end view of the block of FIG. 9;

[0071] FIG. 16 is a lower isometric view of the block of FIG. 9;

[0072] FIG. 17 is an upper isometric view of a block according to a third form;

[0073] FIG. 18 is an isometric view of an alternative embodiment of the block of FIG. 1;

[0074] FIG. 19 is an isometric view of an alternative embodiment of the block of FIG. 9;

[0075] FIG. 20 is an isometric view of a further alternative embodiment of the block of FIG. 9;

[0076] FIG. 21 is an upper isometric view of a block according to a fourth form;

[0077] FIG. 22 is an upper isomeric view of a block according to a fifth form;

[0078] FIG. 23 is a top plan view of a block according to a sixth form; and,

[0079] FIG. 24 is a right side plan view of the block of FIG. 23.

[0080] In the following description, like reference characters designate like or corresponding parts throughout the figures.

DESCRIPTION OF EMBODIMENTS

[0081] An example of a block 1 for automated building construction shall now be described with reference to FIGS. 1 to 8.

[0082] In this example, the block 1 comprises a generally cuboid body 2 of clay comprising a top 4 and a bottom 6 (which are interchangeable with inversion of the block 1), a length extending between a pair of opposed ends 8 and a width extending between a pair of opposed sides 10.

[0083] Each of the sides 10 of the block 1 comprises a plurality of grooves 11. These grooves 11 extend between the top 4 and the bottom 6 of the block 1, and are substantially parallel, identical and equispaced. These grooves 11 will aid render adhesion in instances where render is applied.

[0084] The block 1 is dividable lengthwise into a plurality of block portions 20, where between each pair of adjacent block portions 20 there is at least one dividing slot 12 extending through the body 2 of the block 1 from the top 4 to the bottom 6 and transversely across the block. The or each dividing slot 12 is separated from the opposed sides 10 or an adjacent dividing slot 12 by slender webs 14 which bridge and connect the adjacent block portions 20. In the case of the illustrated embodiment, two aligned dividing slots 12 extend between, or are otherwise separated by three webs 14. The webs 14 include a pair of outer webs proximate the opposing sides 10 and an inner or intermediate web located between the dividing slots 12. The dividing slots 12 provide a cutting guide for a saw blade or the like, and typically each slot 12 is at least the width of a cutting blade employed by a saw of the robotic machine or a saw located in a block manufacturing plant or the like if blocks are cut prior to being loaded into the machine.

[0085] In one form, the thickness of the outer webs 14 at the cut locations created by these dividing slots 12 is minimised to reduce the amount of material which must be cut through in order to divide the block 1. The webs 14 may comprise sharp notches to facilitate their cutting with a chisel, or to facilitate breaking the webs 14 and then knocking a remainder of them off.

[0086] Each of the block portions 20 is nearly identical, having substantially identical overall dimensions, hole dimensions and hole placements.

[0087] Each of the block portions 20 comprise one larger hole 30 at least partially surrounded by a plurality of smaller holes. All of the holes 30, 40, 50 and 60 comprise a rectilinear cross-sectional shape, although other shapes could be employed.

[0088] The larger holes 30 comprise a square cross-sectional shape with rounded corners. Each of the smaller holes 40, 50 and 60 is elongated, with rounded corners.

[0089] A first pair of elongated rectilinear holes 40 is positioned on each side of the larger hole 30 of each block portion 20. Each of these elongated rectilinear holes 40 is positioned between the larger hole 30, and an edge of a side 10 of the block 1.

[0090] Some of the smaller elongated holes could be characterised as slots 50 and 60. A first pair of slots 50 extends parallel to each edge of an end of each block portion 20. The larger hole 30 is between this pair of slots 50.

[0091] Two lengthwise aligned slots 60 extend parallel to each side edge of each block portion 20. One of the elongated holes 40 is positioned between an aligned pair of these slots 60 on each side of the block portion 20.

[0092] Slots 60 create a double shell in the side walls 10. Similarly, slots 50 create a double shell in the end walls 8. These double shells provide thermal insulation, and are suited to accept conventional fasteners (eg wall bolts, picture hooks etc). It should be noted also that the transverse webs adjacent to the dividing slots 12 are thicker than the webs surrounding the large holes or cores 30 to ensure strength on the cut ends.

[0093] Each of the block portions 20 at opposing ends of the block 1 differ from a remainder of the block portions 20 that form a block 1 in that these comprise a pair of transversely spaced protruding tongues or spigots 22 extending between the top 4 and the bottom 6 of the block 1.

[0094] The pair of protruding tongues 22 at one end of the block 1 are transversely offset with respect to the pair of protruding tongues 22 at the opposite end of the block 1. Consequently, if the block is rotated 180 degrees end to end (i.e. reversed endwise) it is the same. This eliminates endedness, such as is the case with a block having male and female ends.

[0095] Each of the tongues 22 comprises a flat surface 24 extending parallel to the surface of the end 8 of the block 1, and a pair of sloping ramp surfaces 26 extending either side down from the flat surface 24 to the surface of the end 8. In use, the ramp surfaces 26 of tongues 22 of two endwise laid blocks can bear against each other, providing opposing surfaces between which adhesive can be applied. The tongues 22 further act as light blocking protrusions such that when blocks 1 are laid in end-to-end abutment, the protrusions block the path of light through any perp gap.

[0096] Referring now to FIGS. 9 to 16 where there is illustrated a block 1A according to a further form. Those parts of the block 1A which are identical (or near-identical) to corresponding parts shown in the block 1 of FIGS. 1 through 8, will be denoted by the same reference numerals and will not be described again in detail.

[0097] In some examples, the block 1 illustrated in FIGS. 1 to 8 is intended for the construction of internal walls of a building structure, and the block 1A illustrated in FIGS. 9 to 16 is intended for the construction of external walls of the building structure (i.e. around the periphery of the building). These will hereinafter be referred to as internal wall block 1 and external wall block 1A. It is however to be appreciated that in other examples, an entire building could be constructed with either block 1 or alternatively 1A. For instance, in some markets, external walls could be constructed with block 1, either in a single leaf or double leaf construction (i.e. a cavity wall).

[0098] Internal wall block 1 has a length of approximately 500 mm; a width of approximately 90 mm; and, a height of approximately 250 mm. In another example, internal wall block 1 may have a longer length of approximately 600 mm; the same width of approximately 90 mm; and a taller height of approximately 400 mm. This larger example of internal wall block 1 is best illustrated in FIG. 18, and is contemplated for use in automated building construction applications where larger internal wall blocks are required or can be handled by the construction robot.

[0099] External wall block 1A has a length of approximately 500 mm; a width of approximately 190 mm; and, a height of approximately 250 mm. In another example, external wall block 1A may have a longer length of approximately 600 mm; the same width of approximately 190 mm; and a taller height of approximately 400 mm. This larger example of external wall block 1A is best illustrated in FIG. 19, and is contemplated for use in automated building construction applications where larger external wall blocks are required or can be handled by the construction robot. In a further example, external building block 1A may have the longer length of approximately 600 mm; a wider width of approximately 290 mm; and the same taller height of approximately 400 mm. This further example is best illustrated in FIG. 20, and is suitable for those applications in automated building construction where additional holes 30 and 60A in external wall block 1A are required which provide more options for routing MEP (Mechanical, Electrical and Plumbing) services through the wall.

[0100] It will be appreciated that further examples of internal 1 and external 1A wall block sizes and geometries other than those disclosed above are envisaged, and the length/width/height of the blocks 1 or 1A may be selected in accordance with handling capabilities of the construction robot, and building design/performance requirements.

[0101] Each of the protruding tongues 22 protrudes approximately 5 mm from an end of the blocks 1 and 1A, giving the blocks 1 and 1A a 500 mm total envelope lengthwise.

[0102] The width of external wall block 1A and each of its block portions 20A is greater than the width of internal wall block 1 and each of its block portions 20. The length of each external wall block portion 20A is the same as the length of each internal wall block portion 20.

[0103] Each external wall block portion 20A comprises a pair of the larger holes 30 spaced apart transversely across the block portion 20A.

[0104] For each of the larger holes 30, each external wall block portion 20A comprises an elongated hole 40, a pair of the slots 50, and a pair of the slots 60.

[0105] In between the larger holes 30, each external wall block portion 20A comprises a further slot 40A between a pair of larger elongate, rectilinear holes 60A. Each of slots 40A and holes 60A has a direction of elongation extending transversely across the external wall block portion 20A.

[0106] Slot 40A has a width which matches the width of hole 40. Each of the holes 60A has a width which matches the length of the slots 60.

[0107] The block 1A is dividable lengthwise into a plurality of block portions 20A, where between each pair of adjacent block portions 20A there is at least one dividing slot 12 extending through the body 2 of the block 1A from the top 4 to the bottom 6 and transversely across the block, the or each dividing slot separated from the opposed sides or an adjacent dividing slot by slender webs 14 which bridge and connect the adjacent block portions 20A. In the case of the illustrated embodiment, three aligned dividing slots 12 extend between, or are otherwise separated by four webs 14. The webs 14 include a pair of outer webs proximate the opposing sides 10 and a pair of inner or intermediate webs located between the dividing slots 12. The dividing slots 12 provide a cutting guide for a saw blade or the like, and typically each slot 12 is at least the width of a cutting blade employed by a saw of the robotic machine or a saw located in a block manufacturing plant or the like if blocks are cut prior to being loaded into the machine. In this example, the webs 14 disposed between the sidewalls and the dividing slots or between adjacent dividing slots have sharp notches and provide a generally convex profile to allow cutting by chisel or breaking and then knocking off tabs.

[0108] In another example, the webs 14 separating the dividing slots from each other and the sidewalls have a rectilinear profile with no notches as shown in FIG. 17. Such an embodiment is more suited for cutting by a saw blade instead of a chisel. In some examples, such as shown in FIG. 23, the intermediate or inner webs 14A between the dividing slots 12 are offset with respect to horizontal ribs or wall sections 84, 86 so they form a T-junction with vertical ribs or wall sections 82 adjacent to the dividing slots 12. This arrangement may be preferable in strengthening the block and reducing the likelihood of cracking.

[0109] It is preferable that the webs 14 which comprise webs to be cut from the block are thinner than other parts of the block. In one example, the webs 14 have a thickness of 5 mm, whilst external wall sections have a thickness of 8 mm and other internal webs of the blocks have a thickness of 6 mm.

[0110] In an alternative example, each of the sides 10 of either internal 1 or external 1A block comprises a plurality of smooth sections 15. These smooth sections 15 extend between the grooves 11 as previously described, and are substantially parallel, identical and equispaced. The purpose of the smooth sections 15 is for aiding in the location or delineation of the larger holes or cores 30 by simply locating the smooth section 15 between the grooves 11 of the internal or external wall block portions 20, 20A. These smooth sections 15 in either of internal wall block 1 or external wall block 1A are best illustrated in FIGS. 21 and 22 respectively, however, it will be appreciated that smooth sections 15 may replace one or more grooves 11 in any one of the previous examples provided.

[0111] Typically, the pair of opposed sides of a block comprise a plurality of grooves that extend between the top and bottom of the block, wherein for each block portion a pair of grooves are separated by a smooth flat side portion that is aligned with and has a width substantially the same as the at least one larger hole. Advantageously, blocks made in accordance with the above embodiments having smooth sections 15 allow a tradesperson or construction technician to quickly identify where the larger holes or cores 30 are located (through which MEP services such as electrical cabling, plumbing services etc. may be routed) enabling them to drill holes etc. in the right location.

[0112] According to a further aspect, there is provided a wall assembly including a plurality of the aforementioned blocks 1 and 1A laid in a plurality of courses, and an adhesive applied between each course of blocks and a successive course to bond these. In this regard, it is to be appreciated that the adhesive is machine applied to the bottom 6 of a block before it is laid onto a lower course. At least two parallel beads of adhesive are typically applied onto the bottom 6 of a block along a lengthwise extent thereof.

[0113] In a further example, the adhesive is further applied onto one or more end 8 faces of a block so as to form a perp joint with an adjacent block in a course. By gluing the perps, flexural strength of the wall is increased which makes the structure more suitable for use in cyclone rated areas. In other examples, there is no adhesive between the perps as application of such is more difficult in the context of an automatic bricklaying machine.

[0114] In one example, the wall assembly includes one or more block portions 20 or 20A divided from the block 1 or 1A or a remainder thereof by a cut made at dividing slots 12. As described in further detail below, a grid system may be used in the design of the wall based around the size of the smallest divisible block portion 20 or 20A which enables every block portion to be used in the construction of the wall with no building waste.

[0115] In another aspect, there is provided a building system using the aforementioned blocks 1 and 1A.

[0116] The blocks 1 and 1A are configured to assemble in a grid system, comprising a 100 mm square grid. The bounding box of each block 1 and 1A is nominally 500 mm long and can be cut into fifths, and be placed on the grid. Internal walls constructed of blocks 1 can tie to external walls constructed of blocks 1A in any position corresponding to a hole of the external wall. The advantage of using such a grid system is that waste is completely eliminated as any remaining off cut of a trimmed block 1 or 1A is of a useful length and can therefore be used elsewhere in the building. The grid system increases the efficiency of the design process and the building process.

[0117] Optionally, the block portions 20 and 20A can be cut at a lengthwise midpoint, creating a partial block portion of 50 mm in length.

[0118] In one form, internal walls are tied into external walls by inserting internal wall blocks 1 between adjacent external wall blocks 1A for at least alternating courses of blocks so that ends of the internal wall blocks 1 lay flush with an outer face of an external wall.

[0119] The sizing and alignment of the holes ensures alignment of holes in blocks 1 and 1A and or block portions 20 and 20A in different courses of a wall assembly, including where these are a part of a keyed in T wall of blocks 1 or 1A, and at corners formed by an intersection of walls formed from blocks 1 and/or 1A.

[0120] All of the holes, and particularly the large holes 30, as well as holes 60A, provide useful access for services such as electrical, plumbing or tie rods. These holes 30 and 60A, as well as the protruding tongues or spigots 22, are also easily recognisable by vision systems to identify block position (e.g. deviation from expected position and orientation) for robotic pick up. The webs around the large holes 30 are suited for grasping by the grippers on the robotic machine, where the fingers of the grippers could be inserted into these holes for grasping. Alternatively, the blocks or block portions could be picked up externally by gripper clamps.

[0121] Advantages of making the block according to the present disclosure from clay include clays thermal and acoustic properties, its fire resistance, and its high dimensional stability and compressive strength. The thermal and acoustic properties of clay are aided by the incorporation of the holes in the block, as well as the fact that the internal webs around the internal holes in the blocks 1 and 1A are offset to increase thermal bridging path length (but not adjacent to cuts, so cut ends are smooth).

[0122] Disclosed herein then is a block which is well suited to use in an automated brick laying machine, for assembly of a wall constructed from the blocks, by the machine. The block is reversible vertically and endwise, and well suited for positional recognition by a vision system, handling by a gripper and division by a cutter, whether incorporated as part of a machine or otherwise.

[0123] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that such prior art forms part of the common general knowledge.

[0124] It will be understood that the terms comprise and include and any of their derivatives (e.g. comprises, comprising, includes, including) as used in this specification, and the claims that follow, is to be taken to be inclusive of features to which the term refers, and is not meant to exclude the presence of any additional features unless otherwise stated or implied.

[0125] In some cases, a single embodiment may, for succinctness and/or to assist in understanding the scope of the disclosure, combine multiple features. It is to be understood that in such a case, these multiple features may be provided separately (in separate embodiments), or in any other suitable combination. Alternatively, where separate features are described in separate embodiments, these separate features may be combined into a single embodiment unless otherwise stated or implied. This also applies to the claims which can be recombined in any combination. That is a claim may be amended to include a feature defined in any other claim. Further a phrase referring to at least one of a list of items refers to any combination of those items, including single members. As an example, at least one of: a, b, or c is intended to cover: a, b, c, a-b, a-c, b-c, and a-b-c.

[0126] It will be appreciated by those skilled in the art that the disclosure is not restricted in its use to the particular application or applications described. Neither is the present disclosure restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the disclosure is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope as set forth and defined by the following claims.