RAPID CONSTRUCTION BLOCK SUITABLE FOR AN INTERIOR WALL

Abstract

The invention relates to a rapid construction block suitable for an interior wall, and its manufacturing method. The rapid construction block comprises an upper support surface, a lower support surface disposed opposite the upper support surface, and four vertically oriented external sides. The rapid construction block further comprises: a plurality of vertical passage openings provided substantially parallel to the upper support surface; the passage openings are provided from the upper support surface to the lower support surface; the vertical passage openings are subdivided by means of straight internal walls; and the vertical passage openings define openings in the upper and lower support surfaces, wherein the openings in the upper support surface are a mirror image of the openings in the lower support surface.and characterized by the fact that the rapid construction block is composed of clay with a silt content between 37% and 60%, the rapid construction block having a compressive strength of at least 18 N / mm2 and in which, in the horizontal section, several internal walls are oriented obliquely with respect to the external sides and intersect.

Description

2 ES2368277 describes a ceramic clay block having a dry vertical wall equipped with a symmetrical tenon assembly, internal cells, and perforations. The perforations are arranged in the internal cells and serve to place a lattice in an arranged position. 5 Numerous losses occur during the production of such base blocks. The present invention aims to find a solution to this. SUMMARY OF THE INVENTION 10 In a first aspect, the invention relates to a rapid construction block adapted to an interior wall comprising an upper bearing surface, a lower bearing surface which is provided opposite the upper bearing surface, and four vertically oriented external sides, the rapid construction block comprising: a plurality of vertical passage openings which are substantially parallel to each other, in which the passage openings are provided from the upper bearing surface to the lower bearing surface,wherein the vertical passage openings are subdivided by straight internal walls, and wherein the vertical passage openings define openings in the upper and lower bearing surfaces, wherein the openings in the upper bearing surface are mirror images of the openings in the lower bearing surface, and characterized in that the rapid construction block is composed of clay with a silt content between 37% and 60% by mass, wherein the rapid construction block has a compressive strength of at least 18 N / mm², and wherein, in the horizontal section, several internal walls are oriented obliquely with respect to the external sides and intersect. In a second aspect, the invention relates to a method for manufacturing a rapid construction block,comprising the steps of: extracting at least one raw material by means of a dredge; preparing a mixture of wet material by mixing and homogenizing the raw material and an additive by means of rollers and double-axis mixers; shaping the mixture of wet material into a rapid building block by extruding the material mixture by means of an extrusion press; and drying and baking the rapid building block in drying chambers and ovens, wherein the rapid building block rests on one or more support surfaces, and wherein the contact area between the rapid building block and one or more of the support surfaces is less than 30%, and preferably less than 20%, of the surface area on the side of the building block BE2024 / 5768 3 rapid on which rapid building block is laid; and characterized by the fact that the raw material includes clay with a silt content between 37% and 60%,and in which process includes the step of providing a plurality of vertical passage openings which are oriented substantially parallel to each other, the passage openings are provided from the upper bearing surface 5 to the lower bearing surface, in which vertical passage openings are subdivided by means of straight walls and in which vertical passage openings defining openings in the upper bearing surface and the lower bearing surface, in which openings in the upper bearing surface are a mirror image of the openings in the lower bearing surface, in which 10 rapid construction block having a compressive strength of at least 18 N / mm², and where, in the horizontal section, several internal walls are oriented obliquely relative to the exterior sides and intersect. It is important that the rapid building block has as small a contact surface as possible with a supporting surface during drying, otherwise the rapid building block will not dry properly,cequiréduirasqualité.Lorsdel'utiliserd'argile avecunefaibleteneurenlimon,ilexisteunrisquequeleblocdeconstructionrapidese pliependalleséchage.L'inventionselonlespremieretdeuxièmeaspectsoffrela possibilitéd'utiliserdel'argileavecunefaibleteneurenlimon(entre 37%et60%)20 sansqueleblocdeconstructionrapidenesedéformependantleprocessusdeséchage. This is achieved by a modified internal structure of the rapid construction block which includes inclined internal walls that intersect. This structure directs the forces of the rapid construction block's own weight along the internal walls, allowing the rapid construction block to retain its shape during drying.25 Furthermore, a rapid construction block with this structure can be easily broken, while maintaining a high compressive strength. Since clay with a low lime content is less expensive and more widely available than clay with a high lime content,The rapid construction block can be produced profitably without compromising quality. 30 DESCRIPTION OF FIGURES The figures are non-limiting examples illustrating the invention and are not intended to limit or interpret the scope of the invention. 35 FIG. 1 illustrates a horizontal section of the rapid construction block. BE2024 / 5768 4 DETAILED DESCRIPTION The invention relates to a rapid construction block made of clay, and a method for manufacturing a rapid construction block of clay. 5 Unless otherwise stated, all terms used in the description of the invention, including technical and scientific terms, are used in the senses generally understood by specialists in the technical field of the invention. For a better understanding of the description of the invention, the following terms are explained explicitly. 10 "A," "an," "the," "a," and "them" refer in this document to both the singular and plural forms except where the context clearly requires otherwise. "A segment" means, for example, one or more segments. 15 The terms "include,""comprising", "composed of", "composed of", "provides", "containing", "containing" are synonyms and are inclusive or open terms indicating the presence of the following, and not excluding or preventing other components, features, elements, members, phases, known or described in the prior art.20 The term "horizontal section" or "section" designates the section of the rapid construction block which is perpendicular to the longitudinal direction of the passage openings. This section therefore shows the shape, for example rhombus, triangle, or pentagon, of the passage openings. 25 The term "sloping internal walls" designates the part of the rapid construction block through which a straight line can be drawn in the horizontal section without crossing a passage opening, said line forming an angle with respect to the external sides of the rapid construction block. 30 The term "triangular points" designates the points in the horizontal section of the openings formed by intersecting or converging sloping internal walls. In a first aspect,The invention relates to a rapid construction block adapted to an interior wall comprising an upper bearing surface, a lower bearing surface which is provided opposite the upper bearing surface, and four vertically oriented external sides. The rapid construction block comprises a plurality of vertical passage openings which are substantially parallel to each other, wherein passage openings are provided from the upper bearing surface to the lower bearing surface, wherein the vertical passage openings are subdivided by means of straight internal walls, and wherein the vertical passage openings define openings in the upper bearing surface and the lower bearing surface. The upper bearing surfaces are a mirror image of the openings in the lower bearing surface, and are characterized by the fact that the rapid construction block is composed of clay with a silt content between 37% and 60% by mass.in which rapid construction block having a compressive strength of at least 18N / mm2 and in which, in the horizontal section, several internal walls are oriented obliquely with respect to the external sides and intersect. Clay and silt are both types of sedimentary materials, but they differ in composition and properties. Clay is mainly composed of very fine particles and has a high water-holding capacity, which makes it plastic and malleable when wet. Silt, on the other hand, is mainly composed of coarser silt particles. A low silt content in clay makes it more plastic, meaning it deforms more easily. Conversely, a high silt content makes clay more rigid and less plastic. To produce rapid construction blocks, clay with a high silt content is primarily used, as it is difficult to produce a good quality rapid construction block from clay with a low silt content. However,The problem with using clay with a low silt content, and therefore increased plasticity, lies in the fact that the rapid construction block deforms easily under its own weight during drying. It is important that the rapid construction block has as small a contact surface as possible with a bearing surface during drying; otherwise, the rapid construction block will not dry properly, which affects its quality. For this reason, a rapid construction block often rests on two support points during drying, as illustrated in Fig. 1, in which the support points are indicated by the reference number. A rapid construction block made of clay with a low silt content, folded downwards during drying in this configuration, will eventually crack, affecting the internal structure and creating a bulge on one side of the rapid construction block. This renders the quick-build block unusable because it is significantly less solid and no longer aligns correctly with other quick-build blocks. BE2024 / 5768 6 To resolve this problem,The internal walls of the rapid construction block are oriented at an angle to the external walls. By intersecting the inclined internal walls, triangular points are created that better withstand gravity. These forces are distributed across these triangular points and then redirected via the inclined internal walls to the external walls. This redistribution and distribution of the five forces allows the loads to be uniformly distributed on the external sides of the rapid construction block. The triangular points thus serve as reinforcement points that counteract the tendency towards deformation or collapse. Furthermore, the orientation of the inclined internal walls also ensures that they can better absorb the forces acting in the direction of gravity. This allows the rapid construction block to support its own weight during the drying process without deformation.even when the clay is still in a relatively moist and soft state. This ensures that rapid construction blocks can be formed from clay with a low silt content without the increased plasticity affecting the shape of the rapid construction block. The elasticity and compressive strength of the rapid construction block are guaranteed because such a force distribution system prevents defects such as cracks or deformations. In one embodiment, the cross-section of the rapid construction block comprises various rhombus shapes. Rhombus-shaped passage openings, provided sequentially, create an inclined orientation of the internal walls, as described above, preventing the rapid construction block from deforming during the drying process. Furthermore, when constructing an interior wall, a quick-build block often needs to be cut to size. This costs a lot of time and money and makes the construction process inefficient. Thanks to the various diamond shapes provided in the quick-build block section,The triangular points are aligned parallel to the outer sides. The quick-build block breaks easily at these triangular points, which facilitates breaking the quick-build block at its size. This eliminates the need to cut the quick-build block to the correct size, making it easier to use. In one embodiment, the cross-section of the rapid construction block comprises various triangular shapes. Triangular passage openings create an inclined orientation of the internal walls, which, as described above, prevents the rapid construction block from deforming during the drying process. Another advantage of the triangular shape is that internal walls are created parallel to the external sides of the rapid construction block. These internal walls function as additional reinforcement lines capable of absorbing forces on the rapid construction block parallel to the external side. In one embodiment, the rapid construction block is composed of clay comprising a calcium oxide (CaO) content between 3,9% and 9.7%, an iron oxide (Fe₂O₃) content between 3.2% and 6.8%, and an organic carbon content between 0.12% and 0.48%. Rapid construction blocks composed of clay with a calcium oxide (CaO) content between 3.9% and 9.7%, an iron oxide (Fe₂O₃) content between 3.2% and 6.8%, and an organic carbon content between 0.12% and 0.48% offer various advantages in terms of production and properties of the rapid construction element. The calcium oxide (CaO) contained in this composition promotes the bonding of the clay particles and contributes to increasing the durability of the rapid construction block by improving the chemical reactions during the firing process. This increased concentration of calcium contributes to greater compressive strength and also reduces the time required for firing, which improves the energy efficiency of the production process. Furthermore, an iron oxide (Fe₂O₃) content between 3.2% and 6.8% guarantees the rapid construction block a higher thermal resistance after the firing process.This contributes to its strength and durability under varying temperature conditions. Iron oxide also gives the rapid construction block a natural red color, which can be aesthetically pleasing without the need for additional colorants. Furthermore, Fe₂O₃ contributes to the hardness of the rapid construction block, making it less susceptible to wear and damage. The organic carbon content, between 0.12% and 0.48%, plays an important role in the combustion process during the firing of the rapid construction block. This organic matter content ensures controlled combustion, which influences the porosity of the rapid construction block, resulting in better insulating capacity and a lighter weight. A balanced organic carbon content also prevents excessive porosity, which weakens the structural integrity of the block. rapid construction. This unique combination of calcium oxide, iron oxide and organic carbon produces a rapid construction block that is both strong and thermally efficient,while production remains efficient and profitable. 35 In one embodiment, the internal walls of the rapid construction block have a minimum thickness of 3.4 mm, and preferably a minimum thickness of 4.5 mm. Despite the presence of numerous passage openings which make the BE2024 / 5768 8 rapid construction block hollow in many places, this minimum thickness provides sufficient structural support to achieve a compressive strength of at least 18 N / mm². The internal walls are also sufficiently thick to absorb the forces of the rapid construction block's own weight during the drying process. 5 In one embodiment, the internal walls of the rapid construction block have a maximum thickness of 15 mm, and preferably a maximum thickness of 10 mm. Internal walls of this thickness are thin enough to maintain the passage openings as large as possible, resulting in a lighter, rapid-construction block. This contributes to increased ease of use.Because a lighter rapid construction block is easier to handle. This increases the efficiency of the construction process, without compromising the strength and durability of the rapid construction block. 15 In one embodiment, the volume of the rapid construction block consists of 35%, and preferably 39%, of passage openings. The larger proportion of passage openings results in a significantly lighter rapid construction block, simplifying transport and handling on site. Furthermore, the passage openings improve the thermal and acoustic properties of the rapid construction block. The open spaces act as natural insulators, allowing the rapid construction block to better retain heat or dampen noise, which is beneficial for energy efficiency and living comfort in the buildings in which they are used. Despite the high percentage of openings,the structural integrity of the rapid construction block is maintained thanks to a careful balance25 between the size of the openings and the thickness and structure of the remaining internal walls. In one embodiment, the passage openings are located at a distance of at least 10 mm, and preferably at least 14 mm, and even more preferably at least 16 mm, from an external side. This distance guarantees sufficient material thickness on the exterior of the rapid construction block, which increases its strength and makes the rapid construction block more resistant to compressive and tensile loads. In addition, it improves thermal insulation and reduces the risk of wear or damage to the exterior. This also contributes to better protection against moisture and frost, which increases the durability and lifespan of the rapid construction block, and thus reduces the maintenance costs of the structures. BE2024 / 5768 9 In one embodiment, the density of the block, the rapid construction block, is at least 1500 kg / m3, and preferably at least 1600 kg / m3,and preferably at least 1680 kg / m³. A rapid construction block with this density offers significant advantages, such as improved compressive strength, durability, and thermal performance. The higher density makes the rapid construction block stronger and more resistant to wear and damage, thus extending the lifespan of the structure. In addition, the higher thermal mass ensures better heat storage, contributing to a more energy-efficient building. Although the rapid construction block is heavier due to its higher density, its greater strength allows for larger openings, which compensates for this and contributes to improved thermal and acoustic properties. In one embodiment, the rapid construction block is symmetrical along at least one axis. This symmetry simplifies the production process, which reduces costs and increases efficiency. It also simplifies the installation of the rapid construction block because it can be used in several directions.This accelerates the processing speed and reduces errors. Furthermore, symmetry improves the storage and transport of the blocks, offering logistical advantages. This makes the rapid construction block not only easier to produce but also more efficient to use on the construction site. In one embodiment, the rapid construction block comprises at least one opening with a horizontal cross-section having a minimum diameter of 25 mm, preferably a maximum of 30 mm, and preferably a maximum of 34 mm, and a maximum diameter of 60 mm, preferably a maximum of 75 mm, and preferably a maximum of 90 mm. An opening of these dimensions is large enough to allow the rapid construction block to be easily grasped by hand or machine, which makes the Rapid construction block, more user-friendly in both manual and automated construction processes. At the same time, structural strength is preserved, as the balance between the minimum and maximum diameters provides sufficient space for a solid grip.without reducing the elasticity of the rapid construction block. This guarantees an optimal combination of ease of use and structural integrity. In another embodiment, the rapid construction block comprises two passage openings having the dimensions mentioned above, preferably the longer axis of said 35 passage openings crosses a part of the longest diameter of the horizontal section of the rapid construction block. These two passage openings provide a grip for pickup by a machine. BE2024 / 5768 10 In one embodiment, at least part of the external surface of the rapid construction block is rough, so that it offers optimal adhesion with a binder such as an adhesive or mortar. In one embodiment, the minimum thickness of at least a portion of the internal walls that are directly connected to an exterior side is greater than the minimum thickness of the internal walls that are not directly connected to an exterior side. When the rapid construction block is placed on the exterior side,The forces of the self-weight of the rapid construction block are redirected along the internal walls towards the opposite external side. Due to the structure of the internal walls, several forces converge within the internal walls and are directly connected to the outside. By giving these internal walls a greater thickness, the internal and external forces are better absorbed, thus preventing deformation of the rapid construction block during the drying process. In another embodiment, an internal wall that is directly connected to an external side has a thickness of at least 6 mm, and preferably at least 6.5 mm, and preferably even more at least 7 mm, and preferably even more at least 7.8 mm. According to a second aspect, the invention relates to a method for manufacturing a rapid construction block,comprising the steps of: extracting at least one raw material 20 by means of a dredge; preparing a wet material mixture by mixing and homogenizing the raw material and an additive by means of rollers and double-axis mixers; shaping the wet material mixture into a rapid building block by extruding the material mixture by means of an extrusion press; and drying and baking the rapid building block 25 in drying chambers and ovens, wherein the rapid building block rests on one or more support surfaces, and wherein the contact area between the rapid building block and one or more of the support surfaces is less than 30%, and preferably less than 20%, of the surface area on the side of the block rapid construction on which rapid construction block is laid; and characterized in 30 that the raw material comprises clay with a silt content between 37% and 60%, and in which process includes the step of providing a plurality of vertical passage openings which are oriented substantially parallel to each other,in which passage openings are provided from the upper bearing surface to the lower bearing surface, in which the vertical passage openings are subdivided by means of straight walls and in which vertical passage openings define openings in the upper and lower bearing surfaces, in which the openings in the upper bearing surface are a mirror image of the openings in the lower bearing surface, in which the rapid construction block has a compressive strength of at least 18 N / mm² and in which, in the horizontal section, several internal walls are oriented obliquely with respect to the external sides and intersect each other. This method of manufacturing a rapid construction block offers the possibility of using Clay with a low silt content (between 37% and 60%) without the rapid building block deforming during the drying process. As mentioned previously,Deformation is avoided by providing inclined internal walls. A rapid construction block made from clay with a low silt content offers the advantage of increased plasticity of the clay mixture. A lower quantity of topsoil in the mixture ensures that the clay is more malleable and moldable during the production process, allowing for easier and more precise shaping of the rapid construction block. This facilitates pressing the clay mixture to give it the correct shape and contributes to consistent quality of the blocks produced. Furthermore, since clay with a low silt content is less expensive and more widely available than clay with a high silt content, the rapid construction block can be produced at a lower cost without compromising quality. In what follows,The invention is described by means of non-limiting examples which illustrate the invention and are not intended or should not be interpreted to limit the scope of the invention. 25 EXAMPLES FIG. 1 illustrates a horizontal section 1 of a rapid construction block according to various embodiments of the invention in its orientation during the drying process, resting on two support points 17. Various passage openings are provided 30 parallel to the vertical axis along the entire vertical length of the rapid construction block. At the top and bottom, the rapid construction block comprises a row of passage openings in the shape of a pentagon. In the center of the horizontal section, the rapid construction block has a large passage opening 8 which serves as a handle for picking up. This large passage opening 8 has a long diameter 35 10 which is at least twice as large as the short diameter 9, the long diameter 9 is substantially parallel to the long outer sides 2. In another embodiment,Two large passage openings are provided symmetrically on the sides BE2024 / 5768 12 left and right. This provides a double grip which makes the rapid construction block suitable for massaging by a machine. Directly above and below the large passageway opening 8, a row of triangular passageway openings 16 is provided. These triangular passageway openings 16 have one side parallel to the upper and lower outer sides of the quick-build block 1, this side facing the large passageway opening 8. This side forms an inner wall parallel to the outer sides, creating the large passageway opening 8. In the right and left parts of the quick-build block 1, the passageway openings are diamond-shaped 18. In addition, there are three small, round passageway openings 13 present on the extreme right and left sides. As diamond-shaped passageway openings 18, the right and left sides cause unnecessary thickening on the outer side 3 because,These round passage openings 13 are added to minimize the weight of the rapid construction block 1. 15 The various pentagonal, triangular and diamond-shaped passage openings are positioned in such a way that various inclined internal walls 15 are created. Some of these inclined internal walls 15 are indicated on the,