Plaster with alignable lace and due productive and constructive processes

Description

Plastering with alignment joints and proper production and construction processes. Field of invention

[001] The present invention relates to the technical sector of civil construction, more specifically to pre-molded and prefabricated elements for civil construction. Fundamentals of the invention

[002] Among the known inventions in the state of the art are utility model MU9002414-1 U2 “CERAMIC BLOCK WITH 6 OR 8 HOLES COATED WITH CEMENT AND PLASTER”, invention patent PI1106446-3 “MASONRY WITH BLOCKS PRE-FIXED BEFORE THE INSERTION OF THE CEMENT MIXTURE AND CONSTRUCTION PROCESS WITH MOLDED MASONRY” which belongs to the same applicant of this application described herein and bricks with various interlocking joints. In summary, the first example represents a brick with a layer of plaster on its side, nothing more, the second a plaster of a size larger than the brick, forming through flanges with the function of formwork, and the third refers to common bricks with interlocking joints to fit them together but without any relation to plaster or formwork function.Now, to be more specific, the first example consists of a brick with its sides coated with plaster, that is, plaster where mortar has been applied to its sides. However, this system does not solve some of the main problems of masonry, such as the continued need to lay block by block, balancing them one by one on top of soft mortar, and also requiring alignment and squaring one by one, row by row. The application itself states that the bricklaying is exactly as in the traditional system, so much so that the holes in the bricks in this system are not even sealed. The invention consists solely and exclusively of a brick with coating on both sides. The second example of the prior art is a patent already granted and which also belongs to the same applicant as this present application. Unlike anything previously known... Petition 870250008580, dated 02 / 02 / 2025, p. 4 / 18 / 6 In this case, the plaster is larger than the brick, leaving some empty spaces between one brick and another that purposefully function as a formwork; that is, the mortar, concrete, or similar material is inserted into these empty spaces, molding the joints since they are delimited by the plaster / formwork and therefore do not need to be leveled and finished as in the previous example. In short: both traditional masonry and the invention mentioned above are like making a sculpture by hand molding, and the second example cited is like making a sculpture using a formwork.The third cited example of the state of the art refers to several bricks or blocks with interlocking joints designed to fit together, but none of these interlocking bricks consist of a plastered brick, much less do they have an interlocking joint in the plaster, which in turn functions as formwork; quite the contrary, in all these interlocking bricks, the plastering is always done manually and at a later stage. As mentioned, the second cited example (patent granted PI 11064463) from the same applicant describes panels with two parallel concrete slabs with bricks between them. The patent prioritized full-wall panels, more intended for construction companies due to the requirement for special equipment for transport and assembly, but the patent lists several variations, including what was stated in the fifth line of page 6 of the descriptive report: "...Furthermore, special blocks (bricks) can be produced with spacing edges so that when these are positioned, these edges or flanges form a closure similar to pre-molded cementitious mix slabs (mortar or concrete). The descriptive report also discusses size variation, specifically mentioning the possibility of producing them in small sizes that can be sold at retail and assembled by any consumer. This is explicitly stated in the last sentence of the patent's descriptive report, referring to a single brick because two bricks would become too heavy to handle. In other words, the patent clearly envisioned the product but did not foresee how to join the various small pieces, and therefore did not anticipate this new construction process for which protection is only now being sought.That patent does mention interlocking joints, but these are cited as one of the ways to join bricks to cement boards, not as a way to position the bricks with plaster as described. Since the priority in that patent was the panels, several features essential for the use of the product in small parts were neglected, and still are. Petition 870250008580, dated 02 / 02 / 2025, page 5 / 18 / 6, for these recently created additional resources, for which protection is requested. Initially, one might imagine that this would only be a case for a certificate of addition, but as stated, the way the product is produced and the way it is constructed using the product brick by brick differ significantly from the previous patent and from what is known in the state of the art. Therefore, it is believed that the fairest course of action would be a patent of invention, since new processes have been created and all processes are classified as patents of invention. In other words, everything already described in the previous patent obviously remains with the protections and terms of that patent, and this application requests protection for the new devices and processes not known in the state of the art. Brief description of the drawings

[003] The invention may be better understood in conjunction with the attached drawings where: Figure 1 shows a perspective view of one side of the object. Figure 2 shows a perspective of the other side of the object. Figure 3 shows a front view of the object. Figure 4 shows a top view of the object. Description of the invention

[004] As mentioned, it is one thing to attach one entire wall panel to another entire wall panel, and quite another to keep hundreds of these plastered bricks aligned and joined to each other even before the mortar has hardened. To solve this problem, an interlocking system has recently been devised, but it is not just any interlocking system, but one created specifically for the needs of this product; that is, it is not a brick with an interlocking system, but a brick with overlapping plaster that creates voids and serves as a formwork (as described up to this point). Petition 870250008580, dated 02 / 02 / 2025, p. 6 / 18 / 6 in the first patent), this type of plaster having an interlocking system (1), that is, it is not a matter of interlocking bricks but rather plasters with an interlocking system (1), quite different therefore from the known interlocking bricks since these still need to receive a subsequent coating, unlike the product described here which is already the joining of the final finish, which represents a considerable advantage as it allows the self-aligning joining of one piece to another since one of the functions of this interlocking system (1) is to self-align the plaster and consequently the building, that is, once interlocked, it is a sign that the plaster is already aligned, thus reducing labor with alignment and squaring and providing a considerable reduction in costs and time.This is also a specific fitting (1) for the type of plastered brick mentioned, as it was designed based on the empty spaces (2) that function as formwork, and although it may seem like a simple solution, it involved considerable inventive activity and numerous simulations were carried out to arrive at this solution, since we needed a solution that would fit all 4 sides of the plasterboard to the adjacent bricks, all at the same time, without overlapping each other and still maintaining horizontal and vertical empty spaces (2) between the bricks. In several attempts this was not possible because some of the corners overlapped another and in other cases a hole remained, which was also undesirable. The solution that worked, fitting all the adjacent bricks without overlapping or leaving holes and still maintaining the empty spaces (2) was the following: consider that the plaster is the external part that will be joined to the others.The fittings (1) described here would be like another identical and parallel inner plate to this one, only slightly offset vertically and horizontally as shown in figures 1 to 4. With this solution it was possible to fit the brick to the other four adjacent bricks while maintaining the empty spaces. This fitting solves a specific problem of the previous patent and may even determine the viability or not of the previous invention with regard to small sizes. Another simple but interesting solution is the insertion of spacers (3) in the fittings (1). If mortar were inserted only in the empty spaces (4), the joints, or seams between the plasters, would remain dry, i.e. without any mortar, and the construction would have an effect of several cracks.These spacers (3) create a grout gap (4) so ​​that when mortar is placed in the empty spaces (2) and the top brick is positioned, this mortar flows from the inside out, allowing mortar to penetrate these grout gaps (4). Petition 870250008580, dated 02 / 02 / 2025, page 7 / 18 / 6 functioning as a kind of grout but, as mentioned, from the inside out. Upon finishing the placement of each brick with plaster, it is enough to remove the excess with a spatula or similar, this being the only final finish. As mentioned, the way of building using individual bricks with plaster also proved to be very different from the version with whole panels of the previous patent, and gave rise to new productive and constructive systems. The production system of the individual brick with plaster itself revealed particularities not known in the state of the art, such as the brick closing system and the use of specific molds prepared to receive brick together with concrete or mortar. The production process of this type of brick with plaster occurs according to the following steps: - In a production line, ceramic bricks are arranged on a flat base with the holes facing upwards. - Small amounts of fluid mortar or similar are inserted into all the holes in the bricks, just enough to seal the bottom of the holes. - After the mortar has cured, small amounts of fluid mortar are inserted into the same holes again, but this time the bricks are turned over so that the holes that were facing upwards are now facing downwards. - After the fluid mortar flows down towards the remaining open holes and cures, the bricks will have the holes sealed on both sides, and this step will be complete. - In another production line, specific molds are used with a delimited space for the brick in the center and plaster extending to the sides of the brick. The mold must also have locks to keep the brick centered until the mortar or similar material cures. - After applying the release agent, the brick with the previously sealed holes is inserted into the mold, positioning it on the fixing clips. - Place the lid on the mold with the top fittings facing inwards. Mortar or a similar material is then inserted into the remaining openings until the form is full. Petition 870250008580, dated 02 / 02 / 2025, p. 8 / 18 / 6 After curing, the mold is removed. A variation of this process replaces the insertion of fluid mortar in the brick sealing step with another method consisting of the following steps. - Spread a thin layer of drier, moldable mortar onto a flat surface. The brick is placed on top of this layer of mortar so that the brick sinks slightly and mortar enters the holes. - The brick is moved, without lifting it, to a clean spot on the flat base so that the mortar remains inside the holes. - After curing, the same process is carried out with the holes on the other side of the brick. The construction process using this type of brick also has steps not known in the prior art, including the specific use of this type of brick (this specific use alone differentiates the process from the entire prior art) and also the interesting feature of the joint gap (4) through which mortar intentionally leaks and automatically performs the jointing of the joints from the inside out. The process takes place according to the following steps: - Specifically, the bricks with plaster fitted with alignment interlocking (1) and spacers (3) described herein are used. - After horizontal joining of some units, mortar is placed in the vertical and horizontal empty spaces (2) in a quantity slightly above what is needed. - Place another row above, forcing the excess mortar to intentionally come out through the vertical and horizontal grout gaps (4). - Using a spatula or similar tool, remove any excess that was intentionally spilled. It is important to highlight that this request is limited to the brick and plaster part, but all the items of a construction such as beams, pillars, foundations, ironwork, electrical, plumbing, doors, windows, etc... can also be included in the building made with these processes.

Claims

1. PLASTER WITH ALIGNING INTERLOCKING AND DUE PRODUCTION AND CONSTRUCTION PROCESSES, this being an independent claim and product, in accordance with the brick with through-plastering forming empty spaces and with formwork function described in the granted patent PI 1106446-3 of the same applicant of this application, characterized by the fact that said plaster is also provided with interlocking (1).

2. PLASTER WITH ALIGNING INTERLOCKING AND DUE PRODUCTION AND CONSTRUCTION PROCESSES, this being a dependent claim and product according to claim 1, characterized by the fact that said interlocking (1) is aligning.

3. PLASTER WITH ALIGNING INTERLOCKING AND DUE PRODUCTION AND CONSTRUCTION PROCESSES, this being a claim dependent on a product according to claim 1, characterized by the fact that said interlocking is also provided with spacers (3).

4. PLASTER WITH ALIGNMENT INTERLOCKING AND CORRESPONDING PRODUCTION AND CONSTRUCTION PROCESSES, this being an independent claim and a process in accordance with the production processes of precast elements for construction, characterized by having innovative and distinct steps from the state of the art, the production process occurring according to the following steps: - In a production line, ceramic bricks are arranged on a flat base with the holes facing upwards. - Small quantities of fluid mortar or similar are inserted into all the holes of the bricks, sufficient only to seal the bottom of the holes. Petition 870250008580, dated 02 / 02 / 2025, page 10 / 18 2 / 3 - After the mortar has cured, small quantities of fluid mortar are again inserted into the same holes, but this time the bricks are turned over so that the holes that were facing upwards are now facing downwards.- After the fluid mortar flows downwards towards the remaining open holes and cures, the bricks will have the holes on both sides sealed, and this step will be complete. - In another production line, specific molds are used with a delimited space for the brick in the center and plaster extending to the sides of the brick. The mold must also have locks to keep the brick centered until the mortar or similar material cures. - After applying a release agent, the brick with the previously sealed holes is inserted into the mold, positioning it on the fixing locks. - The lid is placed on the mold with the mold of the upper fittings facing inwards. - Mortar or similar material is inserted into the remaining openings until the mold is full. - After curing, the mold is removed.

5. PLASTER WITH ALIGNMENT INTERLOCKING AND DUE PRODUCTION AND CONSTRUCTION PROCESSES, this being a process-dependent claim according to claim 4, characterized by the fact that the insertion of fluid mortar in the brick sealing stage is replaced by another method consisting of the following steps: - A thin layer of drier, moldable mortar is spread on a flat base. - The brick is placed on top of this mortar layer so that the brick sinks slightly and mortar enters the holes. Petition 870250008580, dated 02 / 02 / 2025, p. 11 / 18 3 / 3 - The brick is moved without lifting it to a clean location on the flat base so that the mortar remains inside the holes. - After curing, the same process is performed with the holes on the other side of the brick.

6. PLASTER WITH ALIGNMENT INTERLOCKING AND DUE PRODUCTION AND CONSTRUCTION PROCESSES, this being a process-independent claim in accordance with construction processes for masonry buildings, characterized by the fact that the product in question has given rise to a new construction process with steps unknown in the state of the art, the process being carried out according to the following steps: - Specifically, the plastered bricks equipped with alignment interlocking (1) and spacers (3) described herein are used. - After the horizontal joining of some units, mortar is placed in the vertical and horizontal empty spaces (2) in a quantity slightly above what is necessary. - Another row is placed above, forcing the excess mortar so that it intentionally comes out through the vertical and horizontal joint gaps (4). - With a spatula or similar, the excess that has intentionally leaked is removed.

Images