WIRES INSIDE THE WALL

The present invention relates to a masonry element with in-wall wire nests. It is made of gypsum, concrete, other silicates or plastic. It has a prismatic body with positioning element(s) formed on its upper panel and a groove or grooves on its lower panel. The size of the groove or grooves is designed to correspond to the size of the positioning elements. The side panels and the end panels perpendicular to them are rectangular or square. The heights of the side panels and the end panels are the same. The size of the grooves is chosen to be the same size as the size of the positioning elements, the longitudinal edge of the side panels is an integer multiple of the horizontal edge of the end panels.

In the process of construction, wiring causes significant extra work, during which a suitable channel had to be cut in the walls to accommodate the cables, cable channels, and conduits running in the wall. This, in addition to being time consuming, requires significant supplementary work to remove the marks of cutting.

Partition walls commonly used today can be divided into several groups.

- ceramic masonry block, the most common solution to date is the frame ceramic structure. It is a material that has been used for a long time and therefore it is well known among contractors as well as builders. Construction requires neither special skills nor special tools or machines. Its specific weight is significant (80-100 kg/m2). The need for masonry and plaster mortar is high, which means that even with the relatively low price of the element, the finished wall can be more expensive compared to other structures, especially if the need for multiple live work is taken into account, as the production time is longer. The ceramic material is more difficult to carve, engrave and cut.

- Autoclaved aerated concrete partitions are now also widespread. Its advantages are the lower weight (50-70 kg/m2) and the less masonry and plastering mortar. It requires special machines and tools compared to ceramic masonry, but these are not expensive and complicated and they improve productivity. Due to the relatively homogeneous and sufficiently soft, foam-like material, the element is easy to cut and drill, and the grooves are easier to form. Since even the plaster can be omitted, the preparation time is shorter than that of the ceramic masonry. Due to less use of mortar, the structure dries faster due to less water input. At the same time, the price of the element is higher, which in turn is compensated for the finished masonry due to less mortar use and shorter working hours. However, this compensation requires serious professional knowledge, which is rare.

- A drywall is also a common structure used for decades, consisting of a steel profile frame, double-sided drywall, and sound-insulating (typically rockwool) material. The boards are fixed to the frame with steel self-tapping screws. It is light weight (25-45 kg/m2), quick to implement, no plaster required. It needs only smoothing, the water intake is minimal, the workmanship is less dusty and noisy. However, due to the large size, weight, and vulnerability of the boards, material handling is more cumbersome. It is more sensitive to moisture due to the gypsum base material. It requires different, more special machines and tools, and its construction is not part of the traditional masonry work. Fixing into the masonry requires more complicated, special constructions. Mechanical and electrical installation typically takes place after the one sided paneling, so the types of work alternate with each other.

- Gypsum panels and blocks, previously manufactured in industrial scale and circumstances, are out-of-date. Smaller blocks are still widespread in some countries, but their use is insignificant compared to other materials.

Spanish patent ES 2 590 529 A1 discloses a system of ceramic masonry elements having a basic piece, an intermediate (pillar) piece and a lintel piece. The elements can be connected to each other by means of a special, breakable cavity design, at the same time the covered cavities on both sides of the masonry element are also suitable for accommodating the pipes of public utilities.

The solution proposed in this document has several disadvantages compared to the present invention. The design of the indicated elements does not deal with the positioning of the elements relative to each other. The pin-groove design at the end of the elements only positions the elements perpendicular to the wall. Based on this, during the construction it is left to the ability of the person building the masonry to install the elements in such a position that the grooves of the elements come together into a coherent groove. Considering that the elements used in the aforementioned document are made of ceramic base material using extrusion, the geometric design of the elements in such a way by means of which the positioning can be accomplished is not possible due to the manufacturing technology. It is also the responsibility of the contractor to take care to prevent clogging of the grooves when assembling the elements. This is substantially unsolvable if masonry mortar is used. A significant disadvantage is that the retrofitted grooves will have to be repaired after electrical installation. Our proposal offers a solution where the final protective tube is formed by joining the elements, so there is no need to repair the surface afterwards. Thus, even in a masonry with a completely finished surface, a new electrical cable can be laid afterwards. Further, the elements of the aforementioned document are only suitable for forming vertical grooves without carving, also due to the manufacturing technology. The horizontal grooves are formed by rotating the elements, but this does not form a unit with the vertical elements, and further modifications must be made to the elements for assembly. A further disadvantage is that in the case of horizontal grooves, the final groove positions must be known at the time of masonry, so that retrofitting is only possible to a limited extent.

French document FR 2618825 A1 contains a modular building element made of plastic. The building element is essentially a formwork element with pre-formed nests for wires and cables, from which a load-bearing wall structure can be built, and no plastering is required after the wall has been built. This technical solution is fundamentally different from the masonry element according to the present invention, as it does not create a masonry composed of prefabricated elements, but a pattern system which acquires its final shape after concreting. The masonry element acting as a formwork can also be used as a bearing wall as described in the aforementioned document. It does not address the technical problem that the partition walls are built after the roofing is completed and does not provide the option of pouring the concrete from above as the roofing prevents this. There are other disadvantages with respect to the finished masonry. Since only open grooves can be created with the formwork element, the statement that the masonry does not require plastering is unacceptable. Even if complete plastering is not required, the open grooves should be repaired with plaster. This has further disadvantages, as subsequent cable placement is not possible for grooves that are already filled. According to the present invention, the masonry has the final surface (before painting) after it has been finished, so that it is possible to place new wires on a new route even after the masonry has been completely finished. Chinese document CN 207878776 U discloses a ceramic masonry unit having a pin on the top panel and a correspondingly shaped groove on the lower panel. On the side panel of the masonry element - in its center line - there is a vertical and a horizontal nest, the intersection of which has a recess formed for a junction box. This solution creates an open groove system similar to the previous ones. These grooves must be filled with mortar after installing the wires to obtain the final surface of the masonry. This results in additional disadvantages, as later cable placement is not possible in case of grooves that are already filled. As it also provides space for the junction boxes in advance, filling unused grooves with plaster is problematic, as conventionally used plastering mortars cannot be applied in one step. Thus, the open grooves left for the junction boxes actually slow down the construction and make it significantly more difficult to create the final, smooth surface. According to the related document, the elements must be fixed to each other with mortar, but does not provide a solution as to why the grooves do not clog when the mortar is used. Thus, keeping the grooves clean during masonry is left to the mason, which significantly slows down the construction. According to our proposal, the masonry has the final surface (before painting) without any additional plastering, so that even after the completion of the masonry, it is possible to place new wires on a new route.

All three applications are disadvantageous in terms of open, semi-finished grooves. Pre-formed open grooves can only be covered and the wall surface finalized with significant extra work. Once the wall surface has been finalized, it is no longer possible to install additional protective pipes, only with wall engraving. Our solution creates a protective tube system that eliminates the need to install protective tubes of electrical wires. The wall surface of the masonry does not require repair after electrical installation. Further, protective tubes that can be used later remain in the finished masonry.

We are convinced that the presently known solutions do not adequately teach a person skilled in the art to design the tube system of the present invention even if they are familiar with previously available documents.

The purpose of the present invention is to create a masonry element that makes the installation of cables and wires in walls simpler, cheaper, faster and more pleasing aesthetically, as the wiring placed inside the wall for all previously known solutions and masonry materials involves significant additional carving or installation work. It has been realized that if the masonry element is designed in such a way that it contains a cable channel which can be connected vertically and horizontally with a junction box, the cables and wires can be guided in the wall at any height and in any direction. This masonry design also ensures that the wires and cables are only routed in the wall in a regular manner.

Accordingly, the present invention is a masonry element provided with protective tubes for wires inside the wall. It is made of gypsum, concrete, other silicates or plastic. It has a prismatic body with positioning element(s) formed on its upper panel and a groove or grooves on its lower panel. The size of the groove or grooves is designed to correspond to the size of the positioning elements. The side panels and the end panels perpendicular to them are rectangular or square. The heights of the side panels and the end panels are the same. The size of the grooves is chosen to be the same size as the size of the positioning elements, the longitudinal edge of the side panels is an integer multiple of the horizontal edge of the end panels. The nests of the masonry element are vertical and horizontal channels formed perpendicular to each other arranged within the boundary walls of the masonry element. The horizontal channels are formed in the center line of the side panels parallel to the plane of the lower panel. The vertical channels are formed at the corners of the masonry element, advantageously at the vertical center line of the side panel, perpendicular to the plane of the lower panel. The horizontal and vertical channels are formed so that they intersect each other within the masonry element.

Advantageous embodiment of the invention is described in the appended claims. Preferable embodiments of the invention will be described with reference to the accompanying drawings in which:

Figure 1 is the bottom-view of the masonry element provided with two positioning elements and grooves, here the horizontal channels are not shown;

Figure 2 is the side view of the masonry element with three horizontal channels, two positioning elements and grooves on its sides as viewed from the side panel;

Figure 3 is the side view of the masonry element with three horizontal channels, two positioning elements and grooves on its sides as viewed from the end panel;

Figure 4 shows the masonry element with two positioning elements and grooves as viewed from above, where the horizontal channels are not shown; Figure 5 is the masonry element with octagonal positioning elements as viewed from above, where the horizontal channels formed in the horizontal centerline of the masonry element are not shown;

Figure 6 is the side view of a masonry element provided with a horizontal channel in the center of the sides as viewed from the side panel;

Figure 7 shows the masonry element from above with three positioning elements and grooves, where the horizontal channels formed in the horizontal centerline of the masonry element are not shown;

Figure 8 is a perspective view of the masonry elements arranged in two rows and fitted on each other and provided with a junction box, partly in section and partly showing the invisible parts;

Figure 9 shows the masonry element with two positioning elements and grooves as viewed from above, here, the horizontal channels formed in the horizontal centerline of the masonry element are not shown and the design of the vertical nests are curved.

The present invention is a masonry element 1 provided with in-wall wire nests. It is made of plaster, concrete, other silicates or plastic material. It has a prismatic body with positioning element(s) 3 formed on its upper panel 2 and groove(s) 5 on its lower panel. The size of the groove 5 or grooves 5 is designed to correspond to the size of the positioning elements 3. The side panels 6 and the end panels 8 perpendicular to them are rectangular or square. The heights of the side panels 6 and the end panels 8 are the same. The size of the grooves 5 is chosen to be the same size as the size of the positioning elements 3. The longitudinal edge 7 of the side panels 6 is an integer multiple of the horizontal edge 9 of the end panels 8 (Figures 1 - 7). The nests of the masonry element 1 are vertical channels 13 and horizontal channels 12 of the same cross-section formed perpendicular to each other. The protective tubes 11 are arranged in the vertical channels 13 and in the horizontal channels 12. The horizontal channels 12 are formed in the side panels 6 parallel to the plane of the lower panel 4, namely, in the center line of the side panels 6 and/or along the contact line of the upper panel 2 and the side panel 6 and/or along the contact line of the lower panel 4 and the side panel 6. The vertical channels 13 are arranged at the corners of the masonry element 1 and, preferably between the adjacent positioning element 3 and the grooves 5, perpendicular to the plane of the lower panel 4 and to the horizontal edge 9. The vertical channels 13 and the protective tubes 11 at the end panel 8 have a half cross- section so that the masonry elements 1 , after being joined side by side with the end panel 8, provide a final cross-section of the entire closed system of channel 10 and the protective tube 11. If a channel 10 is also formed along the longitudinal edge 7, not only in the center line of the side panel 6 (Figures 2, 3), the horizontal channels 12 and the protective tubes 11 have half cross-sections in order to ensure the final cross section of the entire closed system of the channel 10 and the protective tube 11 .

The vertical channels 13 and the horizontal channels 12 are formed inside the lower panel 4, the upper panel 2, the side panel 6 and the end panel 8 of the masonry element 1. The horizontal channels 12 and the vertical channels 13 intersect each other inside the masonry element 1 forming a common internal space (Fig. 8). The channels 10 can be angular (Fig. 4, 5) or curved (Fig. 9).

At each intersection of the horizontal channels 12 and the vertical channels 13, a junction box 14 may be formed in order to provide cable routing or cable connection. The junction box 14 is generally not required to route the cables in a straight line. It is sufficient to break the channel 10 and the protective tube 11 to the required size at the cable entry and exit points. In the event that it is necessary to route the wire at right angles or to establish a connection between two wires, a junction box 14 must be formed at the intersection of the horizontal channel 12 and the vertical channel 13. This is possible either by simply opening the masonry element 1 at the crossing point of the channels 10 and the protective tubes 11 , but, if necessary, a junction box can be inserted into the masonry element 1 at the crossing point. The intersections and positions of the horizontal channel 12 and the vertical channel 13 can be easily determined due to the regular geometric arrangement of the channels 10 formed in the masonry element 1 . The cross-section of the grooves 5 and the positioning element 3 may be circular or polygonal, optionally rectangular, but any design is suitable which ensures a suitable fit of the channels 10 according to the invention and proper adjustment of the masonry element 1.

The masonry element 1 can be provided with one positioning element 3 and one groove 5 (not shown), but is preferably provided with two (Figures 1 to 6), and can also be provided with several positioning elements 3 and grooves 5 (Fig. 7).

Bricklaying with the masonry element 1 according to the invention is similar to the known masonry elements or bricks. During bricklaying, the masonry elements 1 fit tightly together by means of the positioning elements 3 on the upper panel 2 and the grooves 5 on the lower panel 4 of the masonry elements 1 . The positioning elements 3 fit into the grooves 5 to provide a mechanical connection between the masonry elements 1. This connection allows the masonry mortar to be omitted. The masonry can also be laid “dry” or reinforced using a minimal, ready-to-use adhesive. The ducts in the masonry elements 1 form a continuous line. The vertical channels 13 and the horizontal channels 12 intersect. As a result, the electrical wires, but possibly also the radiator pipes, for example, can be routed in the masonry element 1 .

The advantages of the present invention among the others are that the blocks have a borehole system and a protective tube "network", which can be used as a protective tube for both electrical and mechanical installation. A novelty is the prefabricated pipe system in the elements, which is suitable for replacing the electrical and mechanical protective tubing. The advantage of the positioning element-groove connection is that the elements are connected to each other precisely and in each case in a well-defined position. Therefore, the holes in the elements form a continuous network. The masonry can also be laid “dry” or reinforced using a minimal, ready-to-use adhesive. The vertical and horizontal holes intersect. Although the height size of the elements is relatively free, in the horizontal direction the length dimension of the element is an integer multiple of its width. Therefore, the wall corners and wall intersections can be formed as easily as the straight sections. Due to the design of the elements, the construction time can be significantly reduced. The masonry process is shorter compared to any masonry process in which partition wall blocks are used. The positioning elements provide a mechanical connection between the elements, so no masonry mortar is required. Masonry requires only minimal expertise. The masonry can also be laid “dry” or reinforced using a minimal, ready-to-use adhesive. Due to the dimensional accuracy of the elements after locating and leveling of the first row, the masonry does not require any additional expertise. The wall made of non-carved elements is always straight and vertical. The corners and intersections are perpendicular. The distance between the corners is raster-sized, which is an integer multiple of the length or width of the masonry element. The openings can be bridged over in the masonry using horizontal channels, as the required load bearing can be ensured by sliding an iron bar into the channels. In addition to the fast and accurate implementation, the biggest advantage is the internal tube system made of the masonry elements. Due to this, grooving and protective tubing within the masonry are unnecessary. The electrical cables can be routed both vertically and horizontally in the prefabricated channel system. As the surface of the masonry is not damaged by the electrical installation or installation of the radiators, it is possible to create a final wall surface only made of the masonry elements. Therefore, the elements can be made with a pattern made of convex or concave shapes. In this case, obviously the masonry does not get plastering before painting. A significant result of the present invention is a prefabricated protective tube system in the masonry elements which is suitable for replacing the protective tubes for the electrical wires. The material of the blocks can be of several types. Gypsum, concrete, other silicates or plastics are also suitable. In addition to the strength requirements of the material used, dimensional accuracy is the most important requirement, as the elements provide the desired benefits only with minimal dimensional tolerances.