Patent Application
20060185300
The present invention relates to the general field of construction work, and is particularly concerned with a method and implements to erect walls including a plurality of wall components.
A traditional method for erecting walls including a plurality of wall components, such as bricks, includes laying a first layer of wall components and subsequently adding a layer of mortar on top of the first layer of wall components. Then, a second layer of wall components is positioned over the first layer and mortar is added again on top of the second layer. Usually, mortar is also inserted between the wall components and many layers of wall components are laid on top of each other, as described hereinabove, and the mortar is left to dry. When the mortar is dried, the wall has a relatively strong structural integrity.
However, the wall is typically relatively fragile while the mortar is drying. Accordingly, typically only a limited number of layers of wall components are laid and the mortar is left to dry before adding further wall components on top of these layers. If the wall is relatively tall, a relatively large amount of time is wasted waiting for the mortar to dry.
In addition, laying the bricks requires some skill in order for the work to be done properly. Also, labor costs associated with brick laying are relatively high. In fact, the costs associated with a brick wall are mainly due to labor costs.
With this traditional method, laying of walls having a curved external surface is relatively awkward. Also, there is a need to have a foundation on which to lay the bricks, and since the bricks are maintained on top of each other, there is a need to have relatively wide bricks, and therefore relatively wide foundations. Obviously, such foundations add to the cost of erecting a building.
The freeze and thaw cycle present in many climates can damage the mortar and may render the wall fragile. In this case, there is a need to rapidly repair the wall, as there is a risk that the wall will fall apart.
In addition to this traditional technique, a few implements have been devised to hold wall components, such as bricks, together prior to the addition of mortar. Typically, mortar is required as these implements are only used to position the wall elements at relatively fixed distances therebetween. Also, since these devices only typically connects the wall elements together, but do not connect the wall to any other structure, the wall thereby erected is relatively fragile if no mortar is inserted between the wall components.
Another problem with both the use of previously provided implements and with the traditional methods described herein above, is that laying wall components around windows is a relatively awkward procedure.
Against this background, there exists a need in the industry to provide a new and improved method and implements to erect walls including a plurality of wall components.
An object of the present invention is therefore to provide improved method and implements to erect walls including a plurality of wall components
In a first broad aspect, the invention provides, in combination, a first and a second wall component and a connector for connecting the first and second wall components. The first and second wall components are substantially elongated, each of the first and second wall components including respective first and second ends defining respective first and second end surfaces. The first and second wall components have respectively first and second substantially elongated and substantially longitudinal wall components apertures. The connector includes a base and a first projection extending substantially outwardly from the base, the first projection being insertable between the first end surface of the first wall component and the second end surface of the second wall component. A second projection for engaging the first wall component aperture extends substantially outwardly from the base. A distance between the first and second projections is substantially smaller than a distance between the first aperture and the first end surface of the first wall component.
Advantageously, the connector allows a relatively unskilled user to connect together wall components at a predetermined distance therebetween relatively easily. In addition, the connector improves the structural rigidity of a wall including the connector. The connector also facilitates the erection of curved walls.
In a variant, the connector further includes a third projection for engaging the second wall component aperture. The third projection extends substantially outwardly from the base. A distance between the third and second projections is substantially smaller than a distance between the second aperture and the second end surface of the second wall component.
A non-limiting example of the wall components is a brick including a wall component aperture extending therethrough. The wall component aperture is of substantially oval and substantially uniform cross-section.
In a second broad aspect, the invention provides a wall. The wall includes a plurality of wall components arranged generally in a plurality of layers and a plurality of connectors each for interconnecting a first, a second and a third wall component from the plurality of wall components. Each of the connectors connects the first wall component to the second wall component so that the first and second wall components are at a predetermined side-by-side spacing distance relative to each other. The connector connects the third wall component to both the first and second wall components, the third wall component being in a superposed relationship relative to the first and second wall components with the connector provided between the third wall component and both the first and second wall components. An interconnector connects at least two connectors from the plurality of connectors for substantially preventing a relative movement between the at least two connectors.
In some embodiments of the invention, the wall has a structural integrity large enough to be erected without the use of mortar or any other bonding material.
In a third broad aspect, the invention provides a method for assembling a wall including a plurality of layers of wall components, the method comprising the steps of:
a) superposing above each other the plurality of layers of wall components; and
b) securing to each other the plurality of layers of wall components by interconnecting a plurality of wall components through connectors, each wall component from the plurality of wall components being included in a respective layer from the plurality of layers of wall components.
In a fourth broad aspect, the invention provides a connector for connecting first and second substantially elongated wall components, each wall components having respective first and second ends defining respective first and second end surfaces, the first and second wall components having respectively first and second substantially elongated and substantially longitudinal wall components apertures. The connector includes: a base, a first projection extending substantially outwardly from the base, the first projection being insertable between the first end surface of the first wall component and the second end surface of the second wall component, and a second projection for engaging the first wall component aperture, the second projection extending substantially outwardly from the base. A distance between the first and second projections is substantially smaller than a distance between the first aperture and the first end surface of the wall component.
Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of preferred embodiments thereof, given by way of example only with reference to the accompanying drawings.
In the appended drawings:
In some embodiments of the invention, attachments 20 allow to attach or otherwise secure a connector 16 to an external structure adjacent to the connector 16 to which they are attached. In a specific embodiment of the invention shown in the drawings, the adjacent structure is a frame of a house including wooden boards or any other suitable structure. In this case, the attachment 20 is secured to the wooden boards through screws, nails or to any suitable attachment method.
In other embodiments of the invention, the frame of the house includes any other suitable components. In yet other embodiments of the invention, the attachment 20 is secured to any other suitable external structure that is external and adjacent to the wall 10.
Referring to
Also, the connectors 16 allow spacing from each other the wall components 14 in a given layer 12 at a predetermined distance from each other. In specific embodiments of the invention, the predetermined distance is a variable distance. In other words, in these embodiments the predetermined distance is selected by an intended user from a range of distances.
An example of a suitable wall component 12 is a brick. However, it is within the scope of the invention to have any other suitable wall component.
The interconnectors 18 (not shown in
In some embodiments of the invention, the connectors 16, the attachments 20 and the interconnectors 18 give a structural rigidity to the wall 10 sufficient for the wall 10 to be erected without the use of a binding material, such as mortar. Then, if needed, the bonding material is added between the wall components 14 for esthetic purposes. However, in other embodiments of the invention, mortar is inserted between the wall components 14 to also improve the structural rigidity of the wall 10.
Referring to
In a specific embodiment of the invention, as better shown in
The intercomponent projections 30 and the intracomponent projections 32 allow connecting wall components 14 in the same layer 12 at the variable distance therebetween. To that effect, a distance between an intercomponent projection 30 and an adjacent intracomponent projection 32 is substantially smaller than a distance between an end surface 19 or 17 and the wall component aperture 28 of each wall component 14.
In some embodiments of the invention, as shown in
Referring to
As shown in
One of the intercomponent projections 30 of the connector 16 is inserted between the wall components 14A and 14B, while two intracomponent projections 32 extending from the support surface 34 are inserted respectively within the apertures 28 of the wall component 14A and the wall component 14B.
In a specific use, as seen on
As can be seen in
At a maximal distance between the wall components 14A and 14B, as shown in
At an intermediate distance shown in
In some embodiments of the invention, the intracomponent projections 32 frictionally engage the apertures 28. In this embodiment, the connectors 16 improve the structure rigidity of the wall 10 as opposed to a situation wherein the connectors do not frictionally engage the apertures. In other embodiments of the invention however, the projections 32 do not engage the apertures 28 and are simply inserted within the apertures 28.
Turning back to
The intracomponent projections 32 are substantially cylindrical with a longitudinal axis substantially perpendicular to the support surfaces 34 and 36. In a specific embodiment of the invention, the projections 32 extending from the surface 34 are substantially collinear with the projections 32 extending from the support surface 36. Also, the longitudinal axis of the intracomponent projections 32 is substantially perpendicular to the support surfaces 34 and 36.
In some embodiments of the invention, two collinear intracomponent projections 32 and the base 24 define a connector aperture 40 extending therethrough. However, in alternative embodiments of the invention, the intracomponent projections 32 do not define apertures extending therethrough.
In some embodiments of the invention, some or all of the connectors 16 include a respective attachment 20 or 20′ extending substantially outwardly from the connector 16. In some embodiments of the invention, as seen in
Depressions 44 are defined within the support surfaces 34 and 36 of the connector 16, the depressions 44 being defined around respective intracomponent projections 32 and extending to the peripheral wall 42. The depressions 44 are for receiving the attachments 20. To that effect, the attachments 20 each define an attachment aperture 46.
A specific example of an attachment 20, which is substantially L-shaped, is shown in
The connector 16 includes markings and indicia 54 provided on the peripheral wall 42. The indicia 54 allow positioning of the wall components 14A and 14B at the predetermined distance from each other, as seen in
In some embodiments of the invention, the indicia 54 take the form of substantially rectilinear grooves engraved within the peripheral wall. In other alternative embodiments of the invention, the indicia 54 include a substantially rectilinear raised design over the peripheral wall.
The interconnector 18 extends through the apertures 28 of the wall components 14 and through the connector apertures 40 of the connectors 16. Therefore, the interconnectors 18 solidify the wall components together.
The interconnectors 18 each include a substantially elongated rod 60. The rod 60 is substantially cylindrical. However, it is within the scope of the invention to have rods having any other suitable shape. The rod 60 is shaped to be substantially snugly received within the connector apertures 40.
In some embodiments of the invention, the interconnector includes a plurality of rods 60. Each rod 60 is included in a respective interconnector portion. The rod 60 defines a male segment 62 and a female segment 64. The male segment 62 is defined at an extremity of the rod 60 and the female segment 64 is defined at the other extremity of the rod 60. The male segment 62 of one of the rods 60 is for engaging the female segment 64 of another of the rods 60. To that effect, an outside diameter of the male segment 62 is substantially smaller than an inside diameter of the female segment 64.
In some embodiments of the invention, the rod 60 defines a rod aperture 66 extending therethrough. However, in other embodiments of the invention, the rod 60 does not define an aperture and is instead a solid piece of material.
Referring to
In some embodiments of the invention, the connector 16″ defines connector apertures extending therethrough and therefore the interconnectors engage the foundation in a foundation aperture (not shown in the drawings).
As shown in
One of the window connector 116 and one of the window contour component 77 are better illustrated on
The window connector 160 is very similar to the connector 16, except that half of the base and two of the intracomponent projections 32 are not present in this connector 160. Therefore, a single intercomponent protrusion 130, generally corresponding to the two intercomponent protrusions 30 in the connector 16, is defined in the connector 160. The intercomponent projection 130 is for engaging the indentation 79.
In some embodiments of the invention, it is advantageous to have a wall 10 including half-wall components 14′ in proximity to the window contour elements 77. The half-wall components 14′ are similar to what is obtained by cutting in half one of the wall components 14 in a plane substantially perpendicular to the longitudinal axis of the wall components 14. The half-wall components 14′ help in preserving an offset between the wall components 14 of adjacent layers 12.
In use, a foundation 26 of the house is first built in any suitable manner. Then, the connectors 16″ are laid onto this foundation 26. In alternative embodiments of the invention, the connectors 16″ are laid into cavities defined within the foundation. In yet other embodiments of the invention, the foundation 26 is a concrete foundation and the connectors 16″ are simply pushed into unsolidified concrete while erecting the foundation 26.
Then, a layer 12 of wall components 14 is laid. Subsequently, a layer of connectors 16 is laid onto the layer 12 of wall components 14. A distance between the wall components 14 of this layer 12 is adjusted at a predetermined distance as illustrated in
Afterward, a second layer 12 of wall components 14 is laid onto the first layer. The wall components 14 of the second layer 12 are offset from the wall component 14 of the first layer and spaced apart at the predetermined distance. This offset is such that each of the connectors 16 on top of the first layer of wall components 16 engages two wall components 16 of the second layer 12, as described hereinabove.
Additional layers 12 of wall components 14 are laid on top of each other as described with respect to the first and second layers 12 of wall components 14. When the wall has reached a height substantially equal to a length of one of the rods 60, a rod 60 is inserted into the connectors 16 and the apertures 28 that are substantially aligned. Then, if required, more layers of connectors 16 and wall components 14 are added, as described hereinabove. Rods 60 are also added, as described hereinabove.
In some embodiments of the invention, the wall 10, built as described, is left as is without the use of a bonding material. However, in alternative embodiments of the invention, a binding material, such as mortar, for example, is inserted in between the wall components.
The rods 60 substantially prevent the connectors 16, and consequently in some embodiments of the invention the wall components 14, from moving with respect to each other. Accordingly, a structural rigidity of the wall 10 is greatly improved. This allows erecting the whole wall 10 without requiring the use of mortar or any other binding material, which is only applied after a complete assembly of the wall 10. Therefore, there is no need to wait for the binding material to dry after laying a few layers of wall components, which greatly diminishes a time taken to erect the wall 10.
In addition, an increased structural rigidity of the wall 10 contributes to an improved earthquake resistance of the wall 10 and reduces risks that the wall 10 becomes damaged through any other cause and falls.
In specific embodiments of the invention, the attachments 20 are inserted onto connectors 16 that are aligned with the wood planks and beams of the structure of the house, thereby allowing attaching these connectors to this structure to further solidify the wall 10.
Therefore, the wall 10 and its various components allow erecting the wall 10 without using the mortar and subsequently, to add the mortar which has mainly an esthetic function.
In some embodiments of the invention, the wall is not a straight wall and is instead curved. This curvature is relatively easy to achieve with the wall components 14 and the connectors 16 because of the rounded nature of the intracomponent projections 32 and of the apertures 28.
FIGS. 5 to 7 illustrate alternatives connectors 16′, 16a and 16b which are similar respectively to the connectors 16, 16″ and 116, except that the attachment 20 is replaced in these connectors 16′, 16a and 16b by an attachment 20′ extending integrally from a respective base 24′, 24a and 24b.
In addition, the spacers 200 allow leveling the wall components 14 within a layer 12. To that effect, a number of spacers 200 used, which may include the use of zero spacers (the absence of a spacer), is selected so that the wall components within a level 12 are substantially level with respect to each other.
As shown on
Although the present invention has been described hereinabove by way of preferred embodiments thereof, it can be modified, without departing from the spirit and nature of the subject invention as defined in the appended claims.
