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.
There 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 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.
Like 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.
With 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.
Building 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.
DESCRIPTION OF DRAWINGS
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.
(FIG. 6, 7, 8, 9, 10, 11) The external or internal wood plank of the basic wood block (I). The plank can be inside or outside, even for different wood types, because the cutting of the plank is exactly the same and has been rotated of 180°. Thus the vertical languet (1), which is always in the axis the thickness of the plank, is located at the left end of the plank from above and at the right end in the axis of the plank underneath. The vertical mortise (2) located at the right end of the plank above and located at the left end of the plank underneath. This principle will be applied to all the blocks of the building. This avoids having to cut two different external and internal planks to build the block.
(FIG. 1) Plan view of the internal or external plank. All the dimension of the construction could follow a frame (X*0.5) and specific proportions so that all the construction's elements fit together in length, width and height. For a plank length of (X*6), four dovetail joints (4), carried out on half of the thickness of the plank and over its entire height, are located along the length at (X*0.5), then at (X*2), then at (X*1), then at (X*2), and so on, . . . Thus, the intermediate planks could always overlap themselves and provide a very high compressive strength to the entire construction.
(FIG. 2) The intermediate planks (II) could slip in the external and internal planks perpendicularly. The intermediate planks could slip in the dovetail notches (4) of the internal or external planks. The two vertical ends of the intermediate planks could be vertical tenons (3), in the form of dovetail joints (3), over the entire height of the plank.
(FIG. 3) Detail of the left end of the external and internal planks. Thus the vertical languet (1), which is always in the axis of the thickness of the plank, is located at the left end of the plank above and at the right end in the axis of the plank underneath. (X*I) is the usual commercial height of a wooden plank.
(FIG. 4) Detail of the right end of the external and internal planks. The vertical tenon (2) is located at the right end of the plank which is located above of the wooden block. The vertical tenon (2) is located at the left end of the plank which is located on underneath of the wooden block.
(FIG. 2, 3, 4.5, 9.10) The top of the external planks, or the top of the internal planks, or the top of the intermediate planks or the top of the corner planks, always end with an horizontal tenon. The horizontal tenon is located (5) in the axis of the thickness of the plank.
(FIG. 3, 4, 5, 9, 10) The bottom of the external planks, or the bottom of the internal planks, or the bottom of the intermediate planks or the bottom of the corner planks, always end with an horizontal mortise. The horizontal mortise is located (5) in the axis of the thickness of the plank.
(FIG. 2, 5, 8, 10, 11, 14) Four small holes (7) are drilled in the intermediate planks. These holes are important because they enable to put hooks or steel bars or cables to horizontally attach all the blocks together. A fifth larger central hole (8) is drilled in the intermediate plank. It enables to easily grasp the wooden block. It is possible to place hooks to vertically attach different strata of blocks. The horizontal pipes pass through these large holes. All four or five strata of blocks can be put horizontally reinforcing bars or threaded rods (11) over the entire length of the wall. Threaded rods are bolted (12) at both ends of the wall. With this system of threaded rods, these strata of blocks become real prestressed beams. These threaded rods consolidate the whole construction. It is important if the construction has several floors. This system of reinforcing steel, hidden inside the blocks, gives the whole construction a high resistance.
(FIG. 2, 3, 4) On the upper edge of the external side of the external or internal plank, an edge is inclined (9) to discharge water drops.
(FIG. 6, 7, 8) The basic wooden block (III), has two planks, one external and one internal (I) and four intermediate planks (II). The basic wooden block is made of solid wood. No glue, no nails are required for its installation. Through the dovetails, the intermediate planks are slipped into the external and internal planks. The whole forms a basic wooden block.
(FIG. 8) On each strata of block, the blocks are shifted (X*3), of half the length of a block. At the end, the wall would constitute one body. Since the blocks correspond to a shape of precise dimensions, the intermediate planks fall one above the other. Thus, there is a perfect continuity of planks from the bottom till the top of the walls. Thus, the wooden block wall has a very high resistance to compression. Especially the horizontal steel bar (11) reinforces the wall.
(FIG. 9, 10, 11) The corner plank with notches underneath (IV) has a length (X*3) and height (X*1). At (X*0.5) from both ends, we make two simple cuts at mid-height. The notches are facing downwards (9). The corner plank with notches facing up (V) has a length (X*3) and height (X*1). At (X*0.5) from both ends, we make two simple cuts at mid-height. The notches are facing up (10).The corner planks (IV) fits into the corner planks (V). The corner plank (IV) and the corner plank (V) are slightly different because the tenon (5) is always located on the top of the wooden blocks. The mortise is always located on the bottom of the blocks. Note that the tenons (5) of the corner planks (IV), are interrupted (15) twice. Thereby two strata of corner blocks can also be fitted together if one is rotated at 90 [deg.].
(FIG. 11)
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.
(FIG. 11, 12, 13) The square of wood (VII) can slip into the corner block (VI) to solidify it. In height, the square is the half of the height of the block. Holes (7) are drilled from all sides. Positioned within the corner block, the holes (7) of the piece of wood (VII) are located in front of the holes (7) of the corner block (VI). Thus, the piece of wood (VII) does not impede the passage of the steel rods (11). In the centre of the square of wood (VII), a large hole (16) allows the passage of the vertical reinforcing bars or threaded rods (14) from the foundation to the roof. To strengthen the floor joists (XXXVIII), square pieces of wood are inserted (VII), but are positioned vertically.
(FIG. 13) If necessary, two square pieces of wood (VII) can be fitted inside of the corner block (VI) to solidify it. Two strata of square pieces of wood are the same height as the corner block.
(FIG. 14) A corner block (VI) fits together with two base blocks (III). Reinforcing bars or threaded rods (11) or cables, threaded through the holes (7) and fastened or bolted (12) in the corners of the wall, provide a perfect connection between all the blocks and all the walls.
(FIG. 15) The system of formwork for foundations or concrete columns (VIII).
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.
(FIG. 16) An elongated corner block is used to make the wall's corners. An elongated corner block binds the corner and the wall (XI). It has the shape of a corner block and of a half basic block. Like all blocks, his dimensions are (X*1) in height and length [(X*0.5)+(X*2)+(X*1)+(X*2)+(0.5*X)]=(X*6), it has the same length as a basic block (III). It is necessary to make an external elongated corner plank (IX) and an internal elongated corner plank (X). They each have two dovetails (4), two mortises (10) and four small holes (7). However, the two planks are not perfectly symmetrical. For the plank (IX), the vertical end tenon (1) is on the side of the notches (10), and the other vertical end of the plank is a mortise (2) (IX). For the plate (X), the opposite is true, the mortise (2) is located on the end with the vertical notches, while the mortise (1) is located at the end near the dovetail. The same as for the planks of the wooden blocks, above the plank, there is a tenon (5) and underneath a mortise (6).
(FIG. 16, 17) An elongated corner block (XI) is composed of two intermediate planks (II) and two corner planks (IV) which fit into one elongated external plank (IX) and one elongated internal plank (X).
(FIG. 18) A elongated corner block and a second elongated corner block is placed above, but rotated 90 [deg.]. Thus, thanks to the elongated corner blocks, two corner walls are perfectly bonded together.
(FIG. 19) The elongated corner block also allows a perfect fitting of three or four walls which meet at a corner. Note also that the basic blocks (III), which have exactly the same frame, fit perfectly into the elongated corner blocks (17). The walls can then continue in length or height with basic blocks (III).
(FIG. 20) The beam (XII). The beam is a structuring element which slips inside the blocks. Thus, the height of a beam is (X*0.5). It is therefore the half of a blocks height. The width of the beam is [(2*X)−(2*E)]. Given that “E” is the thickness of the planks. Thus, a beam slides inside the block. The length of the beam depends on the length of the wall. Therefore the length of the beam is regular measure on the dimensions of the blocks nested together, thus [(X*2)+(X*0.5)+(X*0.5)+(X*2)+ . . . )]=[(X*2)+(X*1)+(X*2)+ . . . ] At each measure, on the bottom of the beam, is created a mortise (6) so the beam engages in the tenon (5) located above the intermediate planks from each basic block (I).
(FIG. 20, 21, 22) The end of the beam falls on the corner block. In the centre of the end of the beam, we make a hole (7) so that the reinforcing bar can slip in the end of the beam (14). The reinforcing bar goes vertically through all the corner blocks from the foundation till the roof. At each measure (X*I), we also make holes of diameter (X*0.9) to be able to vertically pass ducts. Thus, several ducts can be placed over the entire perimeter of the building, while being hidden inside the walls. The presence of floor beams doesn't impede the passage of vertical ducts.
(FIG. 23) Therefore, if one wants to insert beams inside corner blocks (XI), it is necessary to cut the top half (18) or the bottom half (19) of the intermediate planks (II). It is also necessary to cut the half top or the half bottom of corner planks with notches to bottom or top (IV) or (V). It is also necessary to cut the half top or the half bottom of external or internal elongated corner planks (IX or X). One obtains the elongated cut corner block (XV), which will be broken down in several ways to respond to all possible scenarios. It is also necessary to cut the top half (18) or bottom half (19) of the intermediate planks (II) of the basic blocks. This gives the basic block with the bottom half of the intermediate plank (XIII) and the base block with the top half of the intermediate plank (XIV).
(FIG. 24) Thus, the beams could insert into the corners and slip in the vertical reinforcing bar (14) which goes from the foundation till the roof. The corner system (XVI) distributes weight all over the entire wall and the forces are forwarded towards the corners where the foundations are located. The corner system could ensure perfect stability of the entire building if several floors are built. In a wall, you will find these beams in the firsts and in the last stacks of blocks. You will also find these beams at each floor, to make thresholds and lintels of doors and windows. You will find these beams under the support of the floor beams or under the roof support beams. You will find this beams anywhere it should be necessary to strengthen the wall. The beams are completely hidden inside the blocks.
(FIG. 25) The top half planks II, IV, IX, X, the is cut (18) for passing the beam's width [(2*X)−(2*E)] and its height (X*0.5). Thus, we obtain new planks, the intermediate plank with the top half cut (XVII). This is simply the intermediate plank (II) who was reduced to half its height (X*0.5). This new plank (XVII) as appropriate is inserted at the bottom or at the top of the basic block (III). This gives the basic block with the top half of the intermediate plank (XIII) in (FIG. 23). Or, this gives the basic block with the bottom half of the intermediate plank (XIV) (FIG. 23). Moreover, in the corner plank (IV) we could practice a top hole with width [(2*X)−(2*E)] and height (X*0.5). We obtain a corner plank with the top cut. (XVIII).
(FIG. 26) Similarly, in the elongated corner planks (IX) or (X), we could practice a top hole or a bottom. The hole has a width [(2*X)−(2*E)] and a height (X*0.5). We obtain different elongated corner planks with the top cut or the bottom cut. (XIX), (XX), (XXII), (XXIII). Two cut corner planks and four cutting elongated corner planks could create all sorts of corner blocks possible to resolve all possible corners where two walls, three or four walls come together from left, right, or in front, when the beams are located on the top or in the bottom part of the block, and thus in all possible directions.
(FIG. 27) To get together several beams in a corner block, the beams must be moved in height (X*005), one of them must be on the half top of the block, and the other in the bottom. And, as appropriate, the beams could be continued beyond the corner block. The corner block intersects two beams and one of them continues (20) (XXIX). Thus, four walls meet at the corner, or in other words, two walls meet there and each wall continues beyond (20). (XXIV). If a beam stops in the corner block (21), we could slide (22) a piece of wood (VII) to reinforce the corner block. A corner block reinforced (XXVI).
(FIG. 28) The corner block for two intersecting beams (XXVII). Here, two walls intersect at right angles and the two beams stop at the corner (21). The corner block for two intersecting beams at right angle but inverted (XXVIII). The corner block cuts the top beam and the bottom beam continues beyond (XXIX).
(FIG. 29) The elongated corner block is cut to let two beams continue beyond (XXX). The beams intersect and continue beyond the block (20). The elongated corner block is cut but the two beams don't continue beyond (21) (XXXI). The elongated corner block is inverse cut, but the two beams don't continue beyond (XXXII). The elongated corner block is cut to let the bottom beam continue beyond (20) (XXXIII).
(FIG. 30) The elongated corner block is cut to let the top beam continue beyond (20) (XXXIV). The elongated corner block is cut to let only one bottom beam which doesn't continue beyond (20) (XXXV). The corner block for two intersecting beams (XXVII). Here, two walls intersect at right angles and the two beams stop at the corner (21). The corner block is made for two intersecting beams at right angle. The bottom beam is located along the elongated corner block. (XXVI). The corner block for two intersecting beams (XXVII). Here, two walls intersect at right angles and the two beams stop at the corner (21). The corner block is made for two intersecting beams at right angle but inverse. The bottom beam is located along the elongated corner block (XXVII).
(FIG. 31, 32) The floor beam (XXXVIII). The floor beam is consisting of basic blocks (III) placed end to end, but positioned vertically. Their dimensions are always multiples of X. For example, you could have height (X*2), but for buildings with larger span, or whether to carry loads heavier than normal, you could increase the height of the beams, (X*3) (X*4), etc. In Width (X*1). And in length the floor beam has to be a multiple of (X*6). The length depends on the length of the wall. Indeed, the basic blocks compose the wall, the length of the wall is also a multiple of (X*6). The count of the beam's length has to add two supports [2*(X*I, 5)] (23). These two support beams are placed on the walls. The floor beams can also be composed of external and internal planks cut at the length of the wall. To strengthen the beam, wooden pieces (VII) are inserted, in height [(X*2)−(2*E)], in width (X*0.5), and various lengths, depending on the holes where they are inserted (X*0.3), (0.9*X), (X*I, 6). Holes (7) are made in order to let place for reinforcing bars or threaded rods (11).
(FIG. 32) In most cases, two reinforcing bars or threated rods (11) are enough. One is located near the top edge and one near the bottom edge. These two reinforcing bars are securely attached to both ends of the beam and strained. Thus, the two reinforcing bars take the weight and reduce the flexion of the beam. Thus, the floor beams are extremely strong and they could support a significant weight from one to the other side of the building. Thus, in many cases, we could spare the construction of partition walls. We could accommodate larger interior spaces with non-load bearing walls. The large centre hole (16) of the square wooden piece (VII) lets inserted reinforcing bars or threaded rods to bind the beams to each other. The holes (16) let enough place to hide horizontal ducts hidden in the floor beams.
(FIG. 33, 34) The beams (XXXIX) have to withstand larger spans or heavier loads. In these cases, one can use a double row of wooden squares pieces (VII) and four strained reinforcing bars. It could become a quite heavy beam, and as such, it has to be handled with a crane. But the beam could also arrive in pieces and could be assembled on the building site.
(FIG. 35) The floor beams (XXXVIII) are placed on the wall at half of the walls thickness. On each floor, the wall always ends with a beam (XII) inserted into the last stack of blocks (XIII). Thus, from outside or inside, the beams are completely hidden. Through this beam, the weight of the floors will be well distributed across the wall and the weight is laid on the corners, and then goes down in the foundations. The floor beams (XXXVIII), are placed on the wall with measures of (X*3), measured between the axis of the beams. On the floor beams (XXXVIII), shall be placed the insulation (25) and a conventional wooden floor (26). Under the floor beams (XXXVIII) one can let apparent floor beams, or apply a ceiling of a conventional construction. The thickness of the floor beams (XXXVIII), can be filled with insulation. One can pass horizontal ducts; these can be related to vertical ducts passing through walls (28).
(FIG. 36) Walls are continued to be built around the floor beams. The needed space to place the beam on the wall has a width of (X*1). The basic blocks (III) are cut with a measure all (X*3), or in other words, a hole of (X*1), then a wooden plank of (X*2), and so on. In fact, the blocks are cut to fit the floor beams (XL). A hole of (X*0.74) is made in the internal side of the basic block (28) (XL). Through this hole, the horizontal ducts located inside the floors beams join the vertical ducts (28). The hooks (27) slide into the holes (7) to fix each block to the bottom or top blocks. The hooks inside the walls (XL) can be used anywhere to fix all blocks together.
(FIG. 37) The system of two beams that clamp the floor beams (XLII). On the two stacks of blocks, or on the supporting end of the floor beams (XXXVIII), a second beam can be put to clamp the floor beams (XII).
(FIG. 38) Threaded rods (29) connect the two beams (XII). The rods (29) are bolted on the top and on the bottom. Thus, this system of two connected beams that surround the floor beams (XLII) makes the construction all-round very robust. This system of two beams (XII) which enclose the floor beams (XXXLIII) puts all the floor weight on the corners and the foundations. Thus, thanks to this system of two beams (XLII), a bearing wall isn't necessary. On this double beam, the wall on the second floor can be built. On the second beam, the first stack will be a basic block with a cut on the bottom half of the intermediate plank (XIV). This block (XIV) fits around the second beam (XII).
(FIG. 39) The interiors of all the blocks of the construction can be filled with fireproof insulation (30). The hooks (27) can bind the piles of wooden blocks. Inside the floor beams, through a hole, the vertical and horizontal ducts can be connected (28).
(FIG. 40) An elongated corner block, on the left side, is cut to insert two contiguous floor beams (XLIII). An elongated corner block, on the right side, is cut to insert two contiguous floor beams (XLIV). Indeed, the elongated corner block has also to leave place for the floor beams which are placed on the walls. Here the cuts are of double width of (X*2). Near the corners, two floor beams are recommended (XXXVIII) to strengthen the edges of the floor. In fact, the edges of the floor must withstand the furniture's weight, which accumulates. Hooks (27) slide into the holes (7) and bind each block to the others.
(FIG. 41) The basic wooden block, on the left side, is cut to let enough place for the floor beams (XLV). The basic wooden block, on the right side, is cut to let enough place for the floor beams (XLVI). Indeed, some basic blocks could also be found at the end of the wall. In this case, the basic wooden block has to let place for the two contiguous floor beams. In the centre of a building, the floor beams can come from two different sides. The basic wooden block is cut on the two sides, left or right, to insert the floor beams (XL VII). The basic block is cut in the centre to insert the floor beams on a partition wall (XLVIII). In case of partition walls, floor beams are supported on both sides of the wall. One must therefore plan the room necessary to let the floor beams (XXXVIII) rely on the wall.
(FIG. 42) Illustration of the basic block for a piece of wall, on the left side, cut to fit the floor beams (XLV). The basic block cut to fit the floor beams on a partition wall (XL VII) and (VIII XL). In the case of a partition wall, floor beams are supported on both sides of the wall.
(FIG. 43) The flat roof system (XLIX).
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.
(FIG. 44) The floor system of the building (L) is virtually identical to the flat roof system (XLIX). Thus floor beams (XXXVIII), all arranged (X*2), based on half the thickness of the wall. Under the floor beams (XXXVIII), there is a first beam (XII). This first beam is inserted into a row of basic blocks with the top half cut of the intermediate plank (XIII). Near the edge, there are two floor beams side by side in order to strengthen the edges, more stressed by the weight of the furniture. The support of the floor beams (XXXVIII) are enclosed by two piles of blocks cut to fit the floor beams (XL) in the wall. Note that in these blocks, a round hole (28) allows that the horizontal ducts which are at the level of the floors are connected with the vertical ducts which are in the walls. On the support of the floor beams (XXXVIII) and the second stack of blocks (XL), a second beam can be placed. The system of two beams encloses the two floor beams (XLII). Indeed, the two beams (XII), beneath and above the floor beams (XXXVIII) are attached to each other by vertical steel bars (29) bolted above and below. Then one can continue to construct up the wall with a first stack of blocks with the bottom half of the intermediate planks is cut (XIV). Then it continues with one or more piles of base blocks (III). In the case of the flat roof system (XLIX), a last row of basic blocks is added with the upper half of the intermediate plank is cut (XIII). In this last stack of block (XIII), a thin beam (XII) is slipped of height (X*0.45), leaving a height of (0.55*X) to slide a gutter (35). Note that the various blocks that are overlapped are connected with each other by hooks (27) that fit into the holes (7) of the intermediate planks (II). These holes (7) are found in all kinds of blocks.
(FIG. 45) The wedge system reinforced by two vertical beams (LI). The vertical beams (XII) are inserted vertically in the end pieces of the outer corners of the walls (37). The two joists go (XII) along the corners from the foundation to the roof. The joists are firmly attached to the blocks of wedges (VI) and (XI), or the corner blocks to elongate (XXIV) to (XXXVII), and the walls, by horizontal steel bars (29) bolted. The horizontal steel rods go through the wall over its entire length. The horizontal steel rods connect two corners on both ends of the wall. Thus, thanks to these joists side by side, the corners become like real columns and thereby extremely solidify the construction. The entire building can rest on its corners that are strong enough to take all the charges and return them back to the foundations. The foundations are always located in the corners. The corner and two walls that intersect there are securely fastened to the foundation through the vertical steel bar that comes from the foundation until the last pile of blocks. The horizontal beams (XII) of the last stack of blocks intersect at the corner. At the corner, the two beams (XII) slip in the vertical rod (29) and are bolted (38). The building can withstand any storm.
(FIG. 46) The columns system (LII). In some situations, it is necessary to raise the whole building or partly. In this case, we must erect columns. The column is formed simply of the corner blocks (VI) reinforced by wooden beams (VII), and stacked on each other. Four beams (XII) are inserted vertically in the four external vertical gaps (37) left by the corner blocks. These beams (XII) climb along the corner blocks from the end of the foundation until the top of the column. The beams are firmly attached to the corner blocks and there between, facing each other, by the horizontal steel bars which pass through the column and bind a beam to the other. Thus, the corners become like real extremely strong columns. The entire building can rest on these columns that are strong enough to take all the charges and return them in the foundation located below them. The column and the walls that intersect there are also firmly attached to the foundation through the vertical steel bar (29) which climbs from the foundation to the roof. The first horizontal beams (XII) on which the walls will climb, intersect at the top of this column. The horizontal beams are inserted and bolted to the vertical rod (38). The vertical rod (29) continues to bind the roof and the entire building to the foundation.
(FIG. 47) In some situations, it is necessary to build a concrete beam belt that is connected to the foundation. For example, in soft ground or soaked or flood, otherwise, in direct contact with the water, all wood construction would perish.
(FIG. 47) Following the fire standards in some countries, for the construction of multi-storey apartments, it may be necessary to create beams belt, using concrete. To do this, the system formwork (VIII) used to build the foundations would be used to build concrete columns. The concrete beams will be grafted on the columns. From the basic blocks (III), one removes the intermediate planks (II) so that it is possible to pour concrete. The concrete beam will adopt exactly the layout of the basic block (III), the same frame, and the tenon (1) and the same mortise (2) at the ends, an external plank (LIII) with the same ends (1) and (2), and, opposite the same plank (LIII), which has been rotated 180 [deg.], its ends (2) and (1) are reversed. In this plank (LIII), holes (7) receive threaded rods. Thus, we create a basic plank with holes (LIII). The horizontal threaded rods (29) bolted (38) at both ends will act as a spacer. Indeed, the threaded rods are used to create a continuous concrete beam, which wasn't possible with basic blocks (III) due to the intermediate plank (II). This gives the formwork of wooden block for concrete beams (LIV). The first stack of the shuttering of the concrete beam will be installed along a beam (XII) placed horizontally. This first beam (XII) will close the bottom of the formwork. Thus, the block formwork will fit on the beam located at the formwork bottom (LV). If necessary, to close the formwork on the top, one can create a formwork block which fits into the beam at the top (LVI). A half formwork plank (LVII) can also be created to form the half block length formwork (LVIII). This half-block is required for shifting alternately blocks of half-length between each course of blocks to create a perfect cohesion of the whole construction.
(FIG. 48) To make the corners, several forms are created from corner formwork planks: the corner plank with notches downwards and a tenon at the vertical end (LIX); the corner plank with notches downwards and mortise at the vertical end (LX); the corner plank with notches upwards and tenon at the vertical end (LXI); the corner plank with notches upwards and mortise vertical end (LXII). The various combinations of corner planks (IV) and (V) with corner planks cut to let pass the concrete (LIX), (LX) (LXI), (LXII), will give different formwork corner blocks: the corner formwork block for two concrete beams (LXIII); the corner formwork block for one concrete beam (LXIV), the corner formwork block for three concrete beams (LXV); the corner formwork block for four concrete beams (LXVI).
(FIG. 49) The formwork system for foundation or for concrete beam and the column (LXVII). If necessary, the formwork system (VIII) used to construct the concrete foundations is used to construct concrete columns. Like the system of wooden columns (LII), four beams (XII) are inserted vertically in the four vertical external holes (37). Here, it illustrates the case of a concrete foundation or a concrete column that joins two concrete beams. Two vertical beams will bear two horizontal beams which serve as background to the formwork of the concrete beam. On the outside, the two longer vertical beams will maintain three heaps of corner blocks (LXIII). Thus, the continuity between the concrete column and concrete beams is achieved (39).
(FIG. 49, 50) A first stack of formwork blocks (LV), inserted on the horizontal beam, (XII) can be placed .After one half formwork block (LVIII) to shift the second stack. One can place a second stack of formwork blocks (LIV). And, finally, place a third pile of formwork blocks (LIV). Reinforcing bars can be horizontally or vertically installed inside the formwork (29). Several vertical ducts (40) can be installed in the axis of the formwork to allow free passage of the future vertical ducts inside the concrete beams. The formwork stays in place. Thus, once the concrete is poured, one can continue to construct the wooden walls with the wasted formwork blocks. Indeed, the basic blocks (III) fit perfectly on the wasted formwork blocks (LIV). Thus, the concrete structure is hidden behind the wooden forms that remain in place. The building with a concrete substrate looks like a building made entirely of wood.
(FIG. 51) For the formwork blocks of the corners, one can also make use of the corner blocks elongated formwork to give strength to benefit the corner blocks for the formwork.
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).
(FIG. 51) For formwork blocks for corners, elongated formwork corner blocks can also be used to give strength. Again, the elongated corner blocks are almost identical to corner blocks, they follow the same characteristics, the same frame, the same tenon and mortise ends (1) (2), the same up and down cuts. Thus, the elongated formwork corner blocks and formwork corner blocks fit into each other. We start by creating elongated formwork corner planks: a first plank with notches downwardly located on the mortise side (2) (LXIX); a second plank with notches downwardly located at the tenon side (1) (LXX); a third plank is a cutting of the first one (LXXI); a fourth plank is a cutting of the second (LXXII). Then the combination of these different planks will give several elongated formwork corner blocks responding to all situations. One can create the elongated formwork corner block for a concrete beam (LXXIII); for two concrete beams in forming an inverted L angle (LXXIV); for concrete beams in forming an L angle (LXXV); for three concrete beams forming a T (LXXVI); for three concrete beams forming inverse T (LXXVII); for three concrete beams forming an inverted T (LXXVIII); for four concrete beams forming a +(LXXIX).
(FIG. 52) The system of sloping roof (LXXX) is required in some areas where it rains or snows a lot. The sloping roof is sometimes imposed by planning regulations. The sloping roof system consists of floor beams (XXXVIII) disposed obliquely .Floor beams (XXXVIII) are attached to pieces of cut joist trapezoidal (41) and placed on the horizontal beam (XII). Slipped into the end of the beams, a cylindrical piece of wood (42), binds all the beams. The trapezoids are firmly attached to the horizontal beam (XII) on which they are based. The roof is placed on a horizontal beam. This horizontal beam is inside the last stack of blocks of the wall. The horizontal beams are firmly attached (38) to the foundation by the vertical bar (29) which climbs inside the corners beginning from the foundation till the roof. Joists cut into triangle (43) forms the slope of the roof. The triangle joists are also bound to the horizontal beam (XII) on which they are based. The triangle joists are the feet where drops the end of the beams (XXXVIII). This structure is covered with an insulator (44), a waterproofing and a gutter (45), of traditional construction.
(FIG. 53). One or more beams (XXXVIII) are placed to triangulate the entire structure of the oblique roof. The beams are connected by a cylindrical wooden beam (42) which is inserted into all the beams and maintains everything together.
(FIG. 54) The system to maintain windows and doors inside the walls (LXXXI). The end of a base block (III) is a perfect support for a door frame or window (46). The door frame blocks will be very strained, especially in an entry door. Wooden pieces (VII) are inserted to strengthen (47) the door. On the top of the frame, a horizontal beam (XII) is inserted. This beam (XII) acts as a lintel and returns loads on both sides of the chassis. Two or more vertical reinforcing bars (29) bolted (38) connecting the lintel beam and the bottom beam of the wall and the upper beam of the wall. Thus, the wall is greatly solidified. In order to shift the blocks alternately along the length, it is necessary to create a basic block half the length (LXXXII). This block is exactly the half of a basic block, the length is (X*3), the other dimensions remain the same. The half block (LXXXII) would find itself along the door or window frame for a stack of blocks on two (48).
(FIG. 55). The door frame or the window frame is then stuck inside the wall by a vertical beam which fills the remaining space (49). And a threshold (50) is placed.
(FIG. 56). The stair (LXXXIII). The stair is obtained by fixing basic blocks (III) together. To make stairs using basic blocks (III), a block based on a slightly different format is created in order to make stairs that fit the formula of two heights for one step. To get a stair format, it is only necessary to reduce the width of the intermediate plank (II). To build stairs, the basic stair blocks would be turned on the side. The height of the first stair is (X*1.43).
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.
(FIG. 57) The stairs (LXXXIII) (M1) and (M2), and so on, are held together by joists (XII). The joists are cut to fit on both sides of the stairs (M1). The joists extend under the step (M2) to maintain (M1) and (M2) all together. Several horizontal steel bars ranging from either side of the stair (53) and several vertical steel bars hold the first stair (M1) with the second stair (M2), (54), and so on. In the same way as the rest of the construction, mounting the stairs is like a construction game. One can install a stair quit quickly.
(FIG. 58). The straight staircase (LXXXIV). In this example, we have 16 stairs, so the staircase rises from (X*20.56). The measure of the stairs often falls on the measures of the height of the pile of blocks. Thus, the third stair is (X*3.98) in height. The height of the seventh is (X*9.08). The height of the tenth is (X*12.91). The height of the fourteenth is (X*18.01). In short, constructions with levels or split levels can be made, the height of its steps would adjust easily. On each side of the stairs, the extended vertical bars (54) serve as railing pillars. On which a handrail can be made (55). The last joist of the last stair could be embedded in the beam of the upper floor to keep the stair stabile (56).
(FIG. 59) The staircase angle (LXXXV). The same principle of insertion of the basic stair blocks (III) is applied to form several stair forms. At the corner, the joists (XII) are slipped in the stairs and attached by horizontal (53) and vertical steel bars (54). The joists slipped in the stairs form the bearing structure (56) and the right angle (57) which would support the second flight of stairs.
(FIG. 60) The staircase angle (LXXXV). The basic stair blocks (III) will contribute to maintain the structure of beams and steel bars. Once the basic stair blocks (III), the joists (XII) and the steel rods (53) and (54) are in place, the staircase forms a single block.
(FIG. 61) The staircase in two parallel flights (LXXXVI).The parallel joists are connected together by horizontal steel bars (53) to hold the bearing (56) and the two flights (58).
(FIG. 62) The staircase in two parallel flights (LXXXVI). The basic stair blocks (III) also maintain the joists structure (XII) and the steel rods (53) and (54). Once the basic blocks, the joists and the steel bars in place, the staircase forms a single block.
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.
The 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.
In 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.
Patent Application
20130104488
