The present invention relates to a link insert for interlocking masonry bricks. The present invention is primarily described with reference to the construction of walls or other structures using link inserts to interlock masonry bricks.
Traditionally, the construction of walls using brick masonry products requires the long and arduous process of putting mortar in between each of the bricks. This requires the mortar to be mixed with specific ratios and applied at a regulated thickness.
There are certain brick systems that propose to use mortarless construction. For example, there are known interlocking concrete blocks that allow for an easy installation, however they generally can only be used for low height walls. There are also certain building blocks that together with insert pieces can be mechanically connected to build walls and partitions, such as that described in U.S. Pat. No. 9,593,480 (Vandenbempt). In this prior art, each insert piece is a plastic hollow sleeve that extends vertically through each block and is placed therein offsite during manufacture of the block. Each insert piece has different opposed ends, namely one end with hooked teeth, and the other end with a circumferential groove. The hooked teeth and circumferential groove are complementary so that the insert's hooked teeth can be coupled to the circumferential groove in a like insert in a block below, and its circumferential groove can be coupled to hooked teeth in a like insert in a block above. A wall built with such bricks having vertically connected inserts suffers from inadequate load limitations, particularly where lintels for doors and windows must be provided within that wall. To overcome this, a further insert arrangement is disclosed in International Patent Publication No. WO 2022/053894 (Vandenbempt) that utilises a plastic insert with a base and vertical component, and rods that engage with the insert. This arrangement further complicates the mortarless construction of walls, both in time as the inserts must be installed in a particular orientation and then the rods fitted, and due to the additional cost of these inserts and rods. An even further insert arrangement utilising a plate-shaped foot and spacers is shown in International Patent Publication No. WO 2024/003697 (Vandenbempt), where holes are provided in protrusions from the insert feet that extend laterally outside of the brick. This insert arrangement is for use where the wall being built is a low load bearing façade wall requiring anchoring to an inner wall, and these inserts are not suited to use with a free-standing load bearing wall.
The present invention seeks to overcome at least one of the disadvantages of the prior art.
In a first aspect the present invention consists of a link insert for interlocking two masonry bricks, said link insert comprising first and second end members and at least one bridging member interconnecting said first and second end members, wherein a first central plane passes through the centre of both said first and second end members, each of said first and second end members having plane symmetry about said first central plane, each half of said first and second end members having a substantially tapered form to engage and seat within at least one hole in either of said two masonry bricks.
Preferably each of said masonry bricks is substantially rectangular in shape, having opposed upper and lower faces on either side of a second central plane, opposed sides, and opposed ends, each of said upper and lower faces has at least a first channel disposed longitudinally therein between said opposed ends, and wherein said at least one hole is two spaced apart holes each of which extend between said first channels, and each hole having a tapered bore portion near its open ends at respective said channels.
Preferably said masonry bricks are laid end-to-end in a first row for the purpose of constructing a wall or other structure, said masonry bricks having their respective channel in said upper face aligned, and said link insert removably connected to same by the lower halves of said first and second end members engaging with holes within respective first channels of said masonry bricks with at least a lower portion of said bridging member lying within said first channels.
Preferably said masonry bricks are laid end-to-end in said first row with other like masonry bricks, said other like bricks similarly removably connected by like link inserts, and a second row of bricks is laid upon said first row of bricks with said link insert and like link inserts disposed therebetween, and the upper halves of said first and second end members of said link insert and like link inserts engaging with holes in the first channels of the lower faces of said second row of masonry bricks with at least an upper portion of the respective bridging members of said link insert and like link inserts disposed within said first channels of the lower faces of said second row of masonry bricks.
Preferably each said masonry brick has at least two second channels in each of said upper and lower faces, each second channel orthogonal to said first channel and disposed at a respective said hole, and each said second channel in said upper face allowing for a like masonry brick to be laid orthogonally to said masonry brick, and said link insert removably connected to same by the lower halves of said first and second end members engaging with holes within said masonry brick and like masonry brick with at least a lower portion of said bridging member lying within said second channel of said masonry brick and the first channel in the upper face of said like brick.
Preferably said link insert is substantially made of plastic, including material which is recycled plastic.
Preferably when either of said first and second end engage and seat within said at least one hole in either of said two masonry bricks, they do so in a tight fit.
Preferably in a second type of link insert a central member is disposed between said first and second end members, said central member like that of said first and second members having plane symmetry about said first central plane, and each half of said central member having a substantially tapered form to engage and seat within said at least one hole in either of said two masonry bricks, and said at least one bridging member is at least first and second bridging members, said first bridging member interconnects said central member to said first end member, and said second bridging member interconnects said central member to said second end member, and said at least first and second bridging members are orthogonally disposed to each other.
Preferably in one embodiment said at least one bridging member is single bridging member.
Preferably in another embodiment said at least one bridging member has at least one curved side.
Preferably in an even further embodiment said at least one bridging member has at least one opening therein.
In a second aspect the present invention consists of a system for constructing walls or other structures, said system using a plurality of link inserts to engage and interconnect with a plurality of masonry bricks, said plurality of link inserts includes at least a first type of link insert; said first type of link insert comprising two end members and at least one bridging member interconnecting said first and second end members, wherein a first central plane passes through the centre of both said first and second end members, each of said first and second end members having plane symmetry about said first central plane, each half of said first and second end members having a substantially tapered form to engage and seat within at least one of two spaced apart holes in either of said two masonry bricks; and each of said masonry bricks is substantially rectangular in shape, having opposed upper and lower faces on either side of a second central plane, opposed sides, and opposed ends, each of said upper and lower faces has at least a first channel disposed longitudinally therein between said opposed ends, and wherein said two spaced apart holes extend between said first channels, and each hole having a tapered bore portion near its open ends at respective said channels.
Preferably two of said masonry bricks are laid end-to-end in a first row for the purpose of constructing said wall or other structure, said masonry bricks having their respective channel in said upper face aligned, and said first type of link insert removably connected to same by the lower halves of said first and second end members engaging with holes within respective first channels of said masonry bricks with at least a lower portion of said bridging member lying within said first channels.
Preferably said two masonry bricks are laid end-to-end in said first row with other like masonry bricks, said other like bricks similarly removably connected by like first type of link inserts, and a second row of bricks is laid upon said first row of bricks with said first type of link insert and like link inserts disposed therebetween, and the upper halves of said first and second end members of said first type of link inserts and like link inserts engaging with holes in the first channels of the lower faces of said second row of masonry bricks with at least an upper portion of the respective bridging members of said first type of link insert and like link inserts disposed within said first channels of the lower faces of said second row of masonry bricks.
Preferably each said masonry brick has at least two second channels in each of said upper and lower faces, each second channel orthogonal to said first channel and disposed at a respective said hole, and each said second channel in said upper face allowing for a like masonry brick to be laid orthogonally to said masonry brick, and said first type of link insert removably connected to same by the lower halves of said first and second end members engaging with holes within said masonry brick and like masonry brick with at least a lower portion of said bridging member lying within said second channel of said masonry brick and the first channel in the upper face of said like brick.
Preferably said plurality of link inserts includes at least a second type of link insert; and said second type of link insert comprising first and second end members like that of said first type of link insert, and a central member disposed between said first and second end members and at least first and second bridging members, said first bridging member interconnects said central member to said first end member, and said second bridging member interconnects said central member to said second end member, said central member like that of said first and second members having plane symmetry about said first central plane, and each half of said central member having a substantially tapered form to engage and seat within said at least one of two spaced apart holes in either of said two masonry bricks, and said at least first and second bridging members are orthogonally disposed to each other.
Preferably in one embodiment said at least one bridging member of said first type of link insert is a single bridging member.
Preferably said at least one bridging member of said first type of link insert has at least one curved side.
Preferably said at least one bridging member of said first type of link insert has at least one opening therein.
Link insert 1 is preferably constructed from a plastic material or composite plastic material having certain engineering properties, including but not limited to withstanding impact loads, being weatherproof, malleable and to some degree is fire resistant. Suitable plastics include but are not limited to High-density polyethylene (HDPE) and Acrylonitrile butadiene styrene (ABS), which may be recycled plastic, and mixed with other filler products. Link insert 1 is preferably made by injection moulding.
Link insert 1 has first end member 2 and second end member 3 interconnected by two parallel bridging members 4 integrally formed therewith. First and second end members 2,3 which are similarly shaped are both hollow, and each have a respective central portion 2a, 3a. First and second end members 2,3 each have plane symmetry about a first central plane P1. Each half of first end member 2 has a tapered form 2t, whilst each half of second end member 3 has a similar tapered form 31. In this embodiment where the link insert 1 is made by injection moulding, bores 5,6 inside the hollow of each of first and second end members 2,3, respectively, has an internal inward draft angle to allow for injection moulding extraction.
Each of the tapered forms 2t,3t of first and second end members 2,3 respectively, are for engaging with a hole 20 in a first embodiment of a masonry brick 10, shown in
Masonry brick 10, hereinafter referred to as brick 10, is used in place of traditional masonry bricks when building walls or other structures in combination with a plurality of link inserts 1. Brick 10 is preferably constructed from traditional masonry materials such as clay or cement.
Brick 10, is substantially rectangular in shape, having opposed upper and lower faces 11,12 on either side of a second central plane P2. Brick 10 also has opposed sides 13,14 and opposed ends 15,16. Both upper and lower faces 11,12 each have a first channel 17 disposed longitudinally therein between opposed ends 15,16. Each of the two holes 20 extend between the first channels 17 in respective upper and lower faces 11,12. Each hole 20 having a tapered bore portion 21 near its open ends at respective first channels 17. Brick 10 also has two shorter second channels 18 in each of upper and lower faces 11,12. Each second channel 18 is orthogonal to first channel 17 and disposed at a respective hole 20.
Each second channel 18 in upper face 11 allowing for a like masonry brick to be laid orthogonally to masonry brick 10, and link insert 1 removably connected to same by the lower halves of first and second end members 2,3 engaging with holes 20 within masonry brick 10 and the like masonry brick, with at least a lower portion of bridging member 4 lying within second channel 18 of masonry brick 10 and first channel 17 in the upper face of like brick.
In this first embodiment the overall length of link insert 1 is about 180 mm, and its height about 60 mm. The external central diameter of the first and second members 2,3 is about 53 mm. Each tapered portion 2t,3t is about 25 mm long about a 10 mm centre. Each tapered portion 2t,3t is at angle of less than ten degrees, and preferably about five degrees. Brick 10 in this embodiment is about 230 mm long, 110 mm wide and 76 mm high.
To commence construction of a wall or other structure, two bricks 10,10a are laid end-to-end in a first row as shown in
As shown in
In a second embodiment, a second type of “ninety-degree” link insert 100 is shown in
The design of brick 10 with its first and second channels 17,18 ensures that linking inserts 1, 100 that are used to construct a wall or other structure by interconnecting rows of bricks 10 are enclosed therein.
Preferably side 14 of brick 10 would be the front “display surface” that would be for example on the exterior of a building. However, either side 13,14 of brick 10 can be used as the display surface.
In the abovementioned embodiments link insert 1 has two (twin) parallel bridging members 4, ninety-degree link insert 100 has two (twin) bridging members 4b, and curved link insert 1C has two (twin) curved bridging members 4c. However, in alternative embodiments, all these link inserts could use a single bridging member to replace the twin bridging members. One such example is link insert Is shown as a fourth embodiment in
In alternative embodiments, the link inserts of the present invention may include openings (or holes) therein for tying or hooking the link insert to cavity hooks or other internal cavity structures.
In both first and second embodiments of masonry bricks 10,110 first and second channels 17,18 are shown with square corner edges, however in other not shown embodiments the square corner edges of these channels 17,18 could be replaced by tapered edges.
For certain wall and other structure construction requirements, masonry bricks 10, 110 may be cut in half at right angles to central plane P2 and used as a “half brick”, and still be able to be connected to masonry bricks 10, 110 using any of the abovementioned link inserts 1,100, 1c, 1s, 200,300. There are several advantages associated with using abovementioned link inserts 1,100, 1c, 1s, 200,300 with masonry bricks 10, 110. Firstly, walls and other structures can be built either permanently or temporarily with out the use of mortar, and secondly the walls constructed are able to carry much greater loads than with the earlier admitted prior art. Furthermore, whilst the link inserts can be made using plastics or plastic composites and various fillers as standard component, the composition may be varied to suit a particular engineering characteristic, such as malleability for fitting of inserts, or increased fire resistance for use in environments with higher risks of fire. Whilst sizing and tolerances may be standardised for universal fitting, the sizing of link inserts and their tapered ends, may vary depending on the size of the bricks, and whether the bricks are made of clay or concrete, and whether the wall or other structure to be built is for permanent or temporary use.
Whilst the link inserts 1,100, 1c, 1s, 200,300 have end members 2,3 with tapered portions 2t,3t of less than ten degrees, they could significantly be different in angle, say a taper of less than forty-five degrees (not shown). Should the taper of 2t,3t, be changed as such, the taper in the holes in the masonry bricks in which they engage would also have to be modified to receive them.
While various embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.
Number | Date | Country | Kind |
---|---|---|---|
2023901665 | May 2023 | AU | national |