Improvement in block with expanded polystyrene core coated with autoclaved or foamed cellular panels, side glass fiber meshes, and micro-concrete around its perimeter

Abstract

The present disclosure relates to a prefabricated block composed of Autoclaved Aerated Concrete (AAC), widely used in civil construction, offering mechanical improvements such as heat resistance, increased pull-out strength, sound absorption, and reduced mass, as well as ease of installation. The invention comprises a rigid self-supporting block (1), made up of two AAC panels (2), two reinforcing glass fiber meshes (3), with said panels (2) enclosing an expanded polystyrene (EPS) core (4), and a micro-concrete layer (C) applied around the entire perimeter of the block (1). In an alternative embodiment, the AAC may be replaced by foamed cellular concrete.

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and takes the benefit from Brazilian Patent Application No. 10 2024 010242 8 filed on May 22, 2024, the contents of which are incorporated herein by reference.BRIEF SUMMARY AND FIELD OF THE INVENTION

[0002] The present patent application refers to a prefabricated block made of expanded polystyrene coated with auto-claved or foamed cellular concrete panels, which receives, on its sides, reinforcing glass fiber mesh panels and a micro-concrete layer applied along its entire perimeter. It is widely used in the civil construction sector, offering improvements in heat resistance, increased pull-out strength, sound absorption, and reduced mass.PRIOR ART

[0003] Known in the prior art is document BR 102019014124-7, by the same applicant, published on Jan. 19, 2021, entitled “IMPROVEMENTS INTRODUCED IN A BLOCK COMPOSED OF EXPANDED POLYSTYRENE CORE COATED WITH MICRO-CONCRETE REINFORCED WITH GLASS: FIBER.” Its description reads: “The present invention patent belongs to the field of civil construction, more specifically to prefabricated components for construction. The object is an innovative product designed to be installed quickly and easily, thereby accelerating the construction process and reducing costs for users. The block may be installed horizontally or vertically and used in both indoor and outdoor settings. Moreover, the product is extremely simple to install: the professional (mason) installs it using only conventional adhesive mortar and basic tools. The block is i versatile and can be manufactured in various dimensions, adapting easily to the needs of each project. One of its possible features is the incorporation of a plumbing system directly into the block, when necessary.”

[0004] The previous document, by the same applicant, aims to present a block that is specially designed and developed with precision and efficiency to offer convenience, speed, and cost-effectiveness. It provides significant advantages in use and makes a new method of constructing small-, medium- / and large-scale buildings accessible to people from all social classes. Furthermore, the block from the previous application aims to provide an option with low production costs yet meeting requirements for strength, safety, and ease of use. It thus offers the market an alternative solution with several potential applications and benefits compared to similar existing products.

[0005] Despite the efficiency of the previous document mentioned above, it does not employ autoclaved or foamed cellular concrete, nor does it disclose the use of glass fiber meshes or the combination of these elements with the expanded polystyrene core and micro-concrete layer. These components, when combined, as described in this new patent application, result in greater operational efficiency of the block for which protection is now sought.

[0006] Therefore, the present patent application, when compared to the block of the prior art, includes significant improvements, such as:

[0007] 35% gain in thermal performance;

[0008] 25% gain in acoustic performance;

[0009] 25% reduction in weight compared to the block disclosed in patent application BR102019014124-7;

[0010] Increase in pull-out resistance from 12 kg per point to 18 kg per fastening point;

[0011] High fire resistance.Advantages of the Invention

[0012] The following are considered advantages of the present patent application:

[0013] Excellent thermal insulation characteristics, ensuring a comfortable environment in all seasons and reducing the need for air conditioning;

[0014] With a density of 550 kg / m3, the block is very light compared to other construction materials, facilitating handling, transport, and reducing structural dimensioning costs;

[0015] The block of this invention weighs 38 kg / m2, while a masonry block weighs 420 kg / m2;

[0016] The Autoclaved Aerated Concrete (AAC) block non-combustible, providing up to 6 hours of resistance at 1200° C. without collapse. The minimum required block size for this is 150×300×600 mm;

[0017] Due to its uniformly distributed closed-cell structure, the AAC has high resistance to moisture absorption;

[0018] Complies with NBR-13438, NBR-13440, NBR-14956-1, NBR-14956-2, and NBR-15575 standards;

[0019] High resistance to compression, tension, impact, and suspended loads.OBJECT OF THE INVENTION

[0020] The purpose of the present patent application is to provide technical improvements aimed at enhancing the operational efficiency of the block, particularly through the incorporation of Autoclaved Aerated Concrete (AAC), to improve sound insulation, fire resistance, weight reduction, and pull-out strength.GENERAL DESCRIPTION OF THE INVENTION

[0021] This patent application essentially relates to a construction block, mainly used in prefabricated building structures, featuring the incorporation of AAC and other coating elements to deliver several construction benefits, such as mass reduction and pull-out strength. Additionally, it offers advantages in terms of acoustic insulation, fire resistance, low maintenance, and low production cost.DESCRIPTION OF THE DRAWINGS

[0022] The invention will now be described in detail, with reference to the attached drawings for better understanding:

[0023] FIG. 1: Perspective view of the self-supporting block of autoclaved or foamed cellular concrete;

[0024] FIG. 2: Exploded perspective view of the self-supporting block of autoclaved or foamed cellular concrete;

[0025] FIG. 3: Top perspective view of the self-supporting block of autoclaved or foamed cellular concrete, with magnified detail;

[0026] FIG. 4: Front perspective view of the self-supporting block of autoclaved or foamed cellular concrete, without the recessed cap.DETAILED TECHNICAL DESCRIPTION

[0027] The IMPROVEMENT IN BLOCK WITH EXPANDED POLYSTYRENE CORE COATED WITH AUTOCLAVED OR FOAMED CELLULAR PANELS, SIDE GLASS FIBER MESHES, AND MICRO-CONCRETE AROUND ITS PERIMETER comprises a rigid self-supporting block (1), composed of two panels (2) of autoclaved aerated concrete, with an intermediate expanded polystyrene (EPS) block (4). Said AAC panels (2) receive lateral glass fiber reinforcement meshes (3), along with a micro-concrete layer (C) around the entire perimeter of the block body (1).

[0028] In its particular configuration, the block (4) serves as a base for assembling the main block (1) and for interlocking with other blocks (1), using a male semicircular shape (M) that fits precisely into the female semicircular shape (F). The longitudinal sides receive AAC panels (2), which are externally reinforced with glass fiber meshes (3) to increase strength and to retain the micro-concrete finish layer (C) around the entire perimeter of the block body (1).

[0029] In an alternative construction, the self-supporting block (1) is composed of two panels (2) enclosing an expanded polystyrene (EPS) block (4), where the panels (2) receive the side meshes (3) and the micro-concrete layer (C) along the entire perimeter of the block (1). In this configuration, the AAC is replaced by a similar material known as foamed cellular concrete, produced through a chemical expansion process that does not require autoclaving. This alternative block (1) maintains the expanded polystyrene core (4) and the interlocking function via the male (M) and female (F) semicircular shapes.

Examples

Embodiment Construction

[0027]The IMPROVEMENT IN BLOCK WITH EXPANDED POLYSTYRENE CORE COATED WITH AUTOCLAVED OR FOAMED CELLULAR PANELS, SIDE GLASS FIBER MESHES, AND MICRO-CONCRETE AROUND ITS PERIMETER comprises a rigid self-supporting block (1), composed of two panels (2) of autoclaved aerated concrete, with an intermediate expanded polystyrene (EPS) block (4). Said AAC panels (2) receive lateral glass fiber reinforcement meshes (3), along with a micro-concrete layer (C) around the entire perimeter of the block body (1).

[0028]In its particular configuration, the block (4) serves as a base for assembling the main block (1) and for interlocking with other blocks (1), using a male semicircular shape (M) that fits precisely into the female semicircular shape (F). The longitudinal sides receive AAC panels (2), which are externally reinforced with glass fiber meshes (3) to increase strength and to retain the micro-concrete finish layer (C) around the entire perimeter of the block body (1).

[0029]In an alternative...

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and takes the benefit from Brazilian Patent Application No. 10 2024 010242 8 filed on May 22, 2024, the contents of which are incorporated herein by reference.BRIEF SUMMARY AND FIELD OF THE INVENTION

[0002] The present patent application refers to a prefabricated block made of expanded polystyrene coated with auto-claved or foamed cellular concrete panels, which receives, on its sides, reinforcing glass fiber mesh panels and a micro-concrete layer applied along its entire perimeter. It is widely used in the civil construction sector, offering improvements in heat resistance, increased pull-out strength, sound absorption, and reduced mass.PRIOR ART

[0003] Known in the prior art is document BR 102019014124-7, by the same applicant, published on Jan. 19, 2021, entitled “IMPROVEMENTS INTRODUCED IN A BLOCK COMPOSED OF EXPANDED POLYSTYRENE CORE COATED WITH MICRO-CONCRETE REINFORCED WITH GLASS: FIBER.” Its description reads: “The present invention patent belongs to the field of civil construction, more specifically to prefabricated components for construction. The object is an innovative product designed to be installed quickly and easily, thereby accelerating the construction process and reducing costs for users. The block may be installed horizontally or vertically and used in both indoor and outdoor settings. Moreover, the product is extremely simple to install: the professional (mason) installs it using only conventional adhesive mortar and basic tools. The block is i versatile and can be manufactured in various dimensions, adapting easily to the needs of each project. One of its possible features is the incorporation of a plumbing system directly into the block, when necessary.”

[0004] The previous document, by the same applicant, aims to present a block that is specially designed and developed with precision and efficiency to offer convenience, speed, and cost-effectiveness. It provides significant advantages in use and makes a new method of constructing small-, medium- / and large-scale buildings accessible to people from all social classes. Furthermore, the block from the previous application aims to provide an option with low production costs yet meeting requirements for strength, safety, and ease of use. It thus offers the market an alternative solution with several potential applications and benefits compared to similar existing products.

[0005] Despite the efficiency of the previous document mentioned above, it does not employ autoclaved or foamed cellular concrete, nor does it disclose the use of glass fiber meshes or the combination of these elements with the expanded polystyrene core and micro-concrete layer. These components, when combined, as described in this new patent application, result in greater operational efficiency of the block for which protection is now sought.

[0006] Therefore, the present patent application, when compared to the block of the prior art, includes significant improvements, such as:

[0007] 35% gain in thermal performance;

[0008] 25% gain in acoustic performance;

[0009] 25% reduction in weight compared to the block disclosed in patent application BR102019014124-7;

[0010] Increase in pull-out resistance from 12 kg per point to 18 kg per fastening point;

[0011] High fire resistance.Advantages of the Invention

[0012] The following are considered advantages of the present patent application:

[0013] Excellent thermal insulation characteristics, ensuring a comfortable environment in all seasons and reducing the need for air conditioning;

[0014] With a density of 550 kg / m3, the block is very light compared to other construction materials, facilitating handling, transport, and reducing structural dimensioning costs;

[0015] The block of this invention weighs 38 kg / m2, while a masonry block weighs 420 kg / m2;

[0016] The Autoclaved Aerated Concrete (AAC) block non-combustible, providing up to 6 hours of resistance at 1200° C. without collapse. The minimum required block size for this is 150×300×600 mm;

[0017] Due to its uniformly distributed closed-cell structure, the AAC has high resistance to moisture absorption;

[0018] Complies with NBR-13438, NBR-13440, NBR-14956-1, NBR-14956-2, and NBR-15575 standards;

[0019] High resistance to compression, tension, impact, and suspended loads.OBJECT OF THE INVENTION

[0020] The purpose of the present patent application is to provide technical improvements aimed at enhancing the operational efficiency of the block, particularly through the incorporation of Autoclaved Aerated Concrete (AAC), to improve sound insulation, fire resistance, weight reduction, and pull-out strength.GENERAL DESCRIPTION OF THE INVENTION

[0021] This patent application essentially relates to a construction block, mainly used in prefabricated building structures, featuring the incorporation of AAC and other coating elements to deliver several construction benefits, such as mass reduction and pull-out strength. Additionally, it offers advantages in terms of acoustic insulation, fire resistance, low maintenance, and low production cost.DESCRIPTION OF THE DRAWINGS

[0022] The invention will now be described in detail, with reference to the attached drawings for better understanding:

[0023] FIG. 1: Perspective view of the self-supporting block of autoclaved or foamed cellular concrete;

[0024] FIG. 2: Exploded perspective view of the self-supporting block of autoclaved or foamed cellular concrete;

[0025] FIG. 3: Top perspective view of the self-supporting block of autoclaved or foamed cellular concrete, with magnified detail;

[0026] FIG. 4: Front perspective view of the self-supporting block of autoclaved or foamed cellular concrete, without the recessed cap.DETAILED TECHNICAL DESCRIPTION

[0027] The IMPROVEMENT IN BLOCK WITH EXPANDED POLYSTYRENE CORE COATED WITH AUTOCLAVED OR FOAMED CELLULAR PANELS, SIDE GLASS FIBER MESHES, AND MICRO-CONCRETE AROUND ITS PERIMETER comprises a rigid self-supporting block (1), composed of two panels (2) of autoclaved aerated concrete, with an intermediate expanded polystyrene (EPS) block (4). Said AAC panels (2) receive lateral glass fiber reinforcement meshes (3), along with a micro-concrete layer (C) around the entire perimeter of the block body (1).

[0028] In its particular configuration, the block (4) serves as a base for assembling the main block (1) and for interlocking with other blocks (1), using a male semicircular shape (M) that fits precisely into the female semicircular shape (F). The longitudinal sides receive AAC panels (2), which are externally reinforced with glass fiber meshes (3) to increase strength and to retain the micro-concrete finish layer (C) around the entire perimeter of the block body (1).

[0029] In an alternative construction, the self-supporting block (1) is composed of two panels (2) enclosing an expanded polystyrene (EPS) block (4), where the panels (2) receive the side meshes (3) and the micro-concrete layer (C) along the entire perimeter of the block (1). In this configuration, the AAC is replaced by a similar material known as foamed cellular concrete, produced through a chemical expansion process that does not require autoclaving. This alternative block (1) maintains the expanded polystyrene core (4) and the interlocking function via the male (M) and female (F) semicircular shapes.

Examples

Embodiment Construction

[0027]The IMPROVEMENT IN BLOCK WITH EXPANDED POLYSTYRENE CORE COATED WITH AUTOCLAVED OR FOAMED CELLULAR PANELS, SIDE GLASS FIBER MESHES, AND MICRO-CONCRETE AROUND ITS PERIMETER comprises a rigid self-supporting block (1), composed of two panels (2) of autoclaved aerated concrete, with an intermediate expanded polystyrene (EPS) block (4). Said AAC panels (2) receive lateral glass fiber reinforcement meshes (3), along with a micro-concrete layer (C) around the entire perimeter of the block body (1).

[0028]In its particular configuration, the block (4) serves as a base for assembling the main block (1) and for interlocking with other blocks (1), using a male semicircular shape (M) that fits precisely into the female semicircular shape (F). The longitudinal sides receive AAC panels (2), which are externally reinforced with glass fiber meshes (3) to increase strength and to retain the micro-concrete finish layer (C) around the entire perimeter of the block body (1).

[0029]In an alternative...

Claims

1. IMPROVEMENT IN BLOCK WITH EXPANDED POLYSTYRENE CORE COATED WITH AUTOCLAVED OR FOAMED CELLULAR PANELS, SIDE GLASS FIBER MESHES, AND MICRO-CONCRETE AROUND ITS PERIMETER, comprising a rigid self-supporting block (1), characterized by autoclaved aerated concrete panels (2), interposed by an expanded polystyrene (EPS) core (4), receiving side glass fiber reinforcement meshes (3), and a micro-concrete layer (C) around the entire perimeter of the block body (1), acting as reinforcement and finish.

2. IMPROVEMENT IN BLOCK WITH EXPANDED POLYSTYRENE CORE COATED WITH AUTOCLAVED OR FOAMED CELLULAR PANELS, SIDE GLASS FIBER MESHES, AND MICRO-CONCRETE AROUND ITS PERIMETER, according to claim 1, characterized by an alternative construction wherein the self-supporting block (1) is composed of panels (2) enclosing an expanded polystyrene core (4), said panels receiving side meshes (3) and a micro-concrete layer (C) around the entire perimeter of the block (1), with the AAC being replaced by foamed cellular concrete using chemical additives for expansion.

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