Lightweight Cementitious Building Forms Using Expanded Polystyrene Beads

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Solution Overview

Problem

Current methods for manufacturing composite building blocks and panels with polystyrene foam and cementitious materials face challenges in achieving optimal adhesion and structural soundness, leading to inconsistent product dimensions and performance due to the use of shredded polystyrene, which results in difficulties in handling and energy efficiency.

Innovation Solution

A method involving mixing substantially dry cementitious material particles with closed cell foam particles to form a dry composition, followed by adding water to create a partially wet composition, which is then transferred and vibrated to form and cure building forms, utilizing expanded polystyrene beads with surface deformations for improved adhesion and reduced weight, and using a system for automated production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If shredded polystyrene is used in composite building blocks, then weight reduction is achieved, but adhesion and structural soundness deteriorate

Engineering Contradiction:

Improveweight of building blockVSAvoidadhesion and structural soundness

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent changes the physical state parameter of polystyrene from shredded form to expanded bead form, which fundamentally alters the material's surface characteristics and adhesion properties while maintaining the weight reduction benefit

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining expanded polystyrene beads with cementitious materials, where the specific morphology of the foam particles (surface deformations) enhances the interfacial bonding between dissimilar materials

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If shredded polystyrene is used in composite building blocks, then weight reduction is achieved, but product dimension consistency deteriorates

Engineering Contradiction:

Improveweight of building blockVSAvoidproduct dimension consistency

Core Design Contradiction:

Weight of moving objectVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent performs preliminary expansion of polystyrene beads before incorporation into the building block, creating uniform pre-expanded particles with consistent dimensions and surface deformations that ensure uniform distribution and consistent final product dimensions

Inventive Principle:

Principle #10Preliminary action

3Strength

If traditional building materials are used, then structural strength is maintained, but energy efficiency and thermal insulation deteriorate

Engineering Contradiction:

Improvestructural strengthVSAvoidenergy efficiency and thermal insulation

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent introduces local quality variations by incorporating insulated core sections with different density and composition than the outer shell, creating zones with optimized thermal insulation properties while maintaining overall structural integrity

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method enhances adhesion, reduces weight, and improves energy efficiency by creating structurally sound, lightweight building forms with consistent dimensions and performance, enabling efficient automated manufacturing and increased thermal insulation.

Implementation Method 1

mixing substantially dry cementitious material particles with closed cell foam particles to form a substantially dry composition

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Implementation Method 2

At least some of the cementitious material particles may adhere to at least some surface deformations on the surface of the closed cell foam particles

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

The method may include transferring and vibrated to form building forms

Methodology Applied

Scientific EffectVibration: Vibration

Data Source

PatentUS9993941B2Methods and systems for the formation and use of reduced weight building blocks forms

Publication Date: 2018.06.12 BAUTEX SYSTEMS LLC

AI summary

In some embodiments, a method may include preparing building forms including at least some cementitious materials. The method for preparing forms may include mixing substantially dry cementitious material particles with closed cell foam particles to form a substantially dry composition. In some embodiment, at least some of the cementitious material particles may adhere to at least some surface deformations on the surface of the closed cell foam particles. In some embodiments, the method may include mixing a second portion of water with the substantially dry composition for a second period of time to form a partially wet composition. In some embodiments, a method may include forming a building form including at least some cementitious materials from the partially wet composition. In some embodiments, the closed cell foam particles may include expanded polystyrene. In some embodiments, a ratio of the water to cementitious material particles may range from 0.20 to 0.40.