WO2005059264A1

WO2005059264A1 - Polyurethane or polystyrene foam block for concrete structures

Info

Publication number: WO2005059264A1
Application number: PCT/MX2003/000110
Authority: WO
Inventors: Antonio Oscar Hernandez Estrada
Original assignee: Hernandez Estrada Antonio Osca
Priority date: 2003-12-17
Filing date: 2003-12-17
Publication date: 2005-06-30
Also published as: AU2003291771A1

Abstract

The invention relates to a homogenous, simplified polyurethane or polystyrene foam block for concrete structures. Said block has a rectangular shape with an internal arrangement of hollow T-shaped vertical cavities that can adopt a trapezoid shape, circular sectors, elliptic or parabolic sector, which always follow the arrangement of one normal figure and a subsequent inverted figure, in addition to a hollow, I-shaped form in which one base is shorter than the other but always following an alternating arrangement. The inner and outer dimensions may differ depending on the density of the foam. The resulting structure after the blocks have been filled with concrete provides load-bearing walls and partition walls with thermal and acoustic insulation capabilities, which are better than those provided by currently used materials. The homogenous, simplified polyurethane or polystyrene foam blocks are produced in existing industrial facilities by simply adding the corresponding molds. Said blocks can be covered with finishings used in walls made of concrete, fired clay, cellular concrete, perlite or adobe blocks. The homogenous, simplified polyurethane blocks can be produced with fixed or portable pressure equipment or by hand in conjunction with the molds, wherein continuous stackings and enclosures are eliminated and better, all-round thermal and acoustic insulation is achieved. The blocks can also absorb horizontal loads and make it possible to build walls with less mass and with anti-seismic capability that is better than the one provided by existing masonry walls.

Description

POLYURETHANE OR POLYSTYRENE FOAM BLOCK FOR CONCRETE STRUCTURES The present invention, as expressed in the statement of this specification, refers to a simplified block of polyurethane or polystyrene foam for concrete structures, homogeneous and hollow, with internal walls structured among themselves, which do not need interior or exterior fittings to form intercalated horizontal and vertical cavities, which when filled with reinforced or simple concrete, form an element with structural stability and load capacity without concrete blind spots and without direct bridges of foam, and that when this block remains in the construction site, they form concrete walls with thermal and acoustic insulation. At the upper, lower, front and rear ends, it contains homogeneous padlocks that interconnect the blocks horizontally and vertically, for the construction of concrete walls, thermally insulated.

FIELD OF THE INVENTION

The present invention relates to hollow blocks of polyurethane or polystyrene foam that are part of the building of thermally insulated concrete walls. It contains inside, walls that form intercalated cavities, which when filled with concrete, form a structure of columns and beams without concrete blind spots and without direct foam bridges.

OBJECT OF THE INVENTION

Conventional blocks of concrete and / or some other material have shown over time that they have great deficiencies, such as the lack of thermal insulation, the amount of material, its weight, and the properties of resistance to seismic movements, because the materials and the system used is not ideal to contain this type of inclement nature, causing major disasters and the use of different types of energy to make them functional, this generates many extra costs in implements and labor as well as a great waste of resources in maintenance. The objective of this block of structured polyurethane and polystyrene foams for construction is to increase the strength properties of the constructions and provide them with insulating and thermal properties, thereby lowering the excessive expenditure on conventional materials, replacing the blocks that were conventionally used by This new block of structured polyurethane and polystyrene foams for construction.

This invention relates to a homogeneous block of polyurethane foam or polystyrene foam, simplified and without attachments, rectangular in shape with intercalated internal walls, forming vertical and horizontal cavities, which when filled with concrete, form a structure without points Blind concrete and no foam bridges. The homogeneous blocks of polyurethane or polystyrene foam are of different densities, according to their height and the longitudinal measurements of the cavities in the form of capital letter T, and inverted T, which together with the beams, formed when filled with concrete and a steel rod reinforcement, end up providing a thermally insulated concrete structure, and be a permanent part of the building in walls with high stability and load capacity, derived from the corresponding structural calculation.

The blocks have a higher ap art, an analogous one for reinforced reinforcement, and at the same time they leave a channel to insert the lower padlock of the block inserted above, to go forming a wall vertically, which when filled with concrete, will prevent a blind spot of concrete in the horizontal joint. In addition, in its front part it has a padlock that is inserted in the back of another block, to form a wall horizontally. This padlock forms a vertical hole that will be filled with concrete and will prevent a blind spot of concrete on the vertical joint. The erection of walls, of polyurethane foam or polystyrene, to be filled with reinforced concrete, do not need any extra attachment to the foam block. The measures of the blocks provide a rapid advance in the erection of areas of walls, highlighting the elimination of castles and running walls. The combination of blocks, of polyurethane or polystyrene foam, and reinforced concrete, derived from the use of this invention, is superior in its capacity of thermal and structural insulation, to any other material currently used in the construction of walls. The manufacture of polyurethane foam blocks can be carried out with a portable proportioning equipment and molds, where required.

The mentioned blocks can also be manufactured in expanded polystyrene or extracted polystyrene, applying the corresponding measurement and density specifications, always following the same arrangement of walls, columns and beams.

The blocks are manufactured in smaller longitudinal measurements with the same densities and arrangement of cavities for modulation in horizontal development, as well as with different heights and densities for vertical modulation.

BACKGROUND

Homogeneous polyurethane foam blocks to be filled with concrete have no prior art background. In polystyrene there are a variety of blocks that are formed with separate panels, which are made by plastic components, small rings, small structures, sheet or plastic guides or structure guides, except for one block that is homogeneous with plastic guides for placement. All these blocks have the particularity of having blind spots of concrete and foam bridges, so that their insulating capacity on the entire exposed surface is not constant in the finished wall and that gives them some failure to perpendicular penetration. In addition, due to the interior dimensions of the cavities, the concrete consumption is much higher than the structurally required. The building of walls with polyurethane or polystyrene foam blocks, forms a structure based on columns and beams, which with the appropriate calculation, provide walls with great load capacity and stability. References: Patent documents in the United States of America.

Patent Number Author Date 37SS020 1/74 Gregori 4223501 9/80 De Lozier Howard 4439967 4/84 Dielenberg Olif 4516372 5/85 Grust George 4577447 3 / S6 Doran William E. 4604843 8/86 OTT Renaud - Jalabert Georges 4698947 10/87 McKay Harry 4706429 11/87 Young David A. 4731968 3/88 Obino Dansela 4748659 5/88 Meilleur 4750308 6/88 McKay Harry 4SS4382 12/89 Horobin 4894969 1/90 Horobin 4949515 8/90 Krecke 4967528 11/90 Doran 5040344 8 / 91 Durand 50740SS 12/91 Bergeron 5107648 4/92 Roby 5123222 6/92 Guarriello & Bros. 5140794 8/92 Miller 5371990 12/94 Salah Uddin 5390459 2/95 Mensen 5482933 7/95 Phillippe 5449971 10/95 Sparkman 5497592 3/96 Boeshart 5566518 10/96 Martin et al. 5570552 11/96 Nehring 5611183 3/97 Kim 5625989 5/97 Brubaker et al.

5657600 8/97 Mensen

5701710 12/97 Tremelling

5704180 1/98 Boeck 5735093 4/98 Grutsch

5845449 12/98 Vaughn et al.

5852907 12/98 Tobin et al.

5857300 1/99 Gates

5890337 4/99 Boeshart 5896714 4/99 Cymbala et al.

5992114 11/99 Zelinsky et al.

6079176 6/00 Westra et al.

6151856 11/00 Shimonohara

6176059 01/01 Cantarano et al. 6240692 6/01 Yost et al.

6247280 6/01 Grinshpun et al

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6526713 3/3 Moore, Jr.

Documents in other countries. -

FR 2394647 5/91 Guarriello & Bros. FR 5024035 6/91 Hanson &

DESCRIPTION

The characteristic details of this novel polyurethane or polystyrene foam block for concrete structures are clearly shown in the following description and in the accompanying drawings, following the same reference signs to indicate the parts and figures shown.

Figure 1 shows, a side elevation.

Figure 2 shows a plan view in its upper part. Figure 3 represents a plan view in its lower part

Figure 4 shows a front elevation view.

Figure 5 shows a rear elevation view.

Figure 6 shows an isometry seen in its upper part

Figure 7 shows an isometry seen in its lower part. Figure 8 shows an isometry seen in its upper part with the internal characteristics that arise when removing a side face of the block.

Figure 9 block T, shows an isometry in top view with the internal characteristics that arise when removing three external faces.

Figure 10 shows a block-corner to which an internal face and an external face are removed.

Figure 11 shows a block-enclosure or foundation beam-block to which a side face has been removed.

Figure 12 shows a block-enclosure or block-foundation beam seen in front elevation. Figure 13 shows a block-column seen its top.

Figure 14 shows a block-column in the corner, seen at the top.

Figure 1 5 shows a b-block-column with a face to the year of the block, which is the top country.

Figure 16 shows a curved block seen at its top. Figure 17 shows a foundation beam seen in front elevation.

Figure 18 shows a block-beam seen in front elevation.

Figure 19 shows the resulting structure inside the blocks. With reference to the figures listed, a simplified block of polyurethane or polystyrene foam, homogeneous and hollow, is made in one piece, in which the characteristics that give rise to the interleaved arrangement of the internal vertical walls ( 9), (10), (11), (12), (13) and (14), structured among themselves and that together with the lateral external walls (4), give rise to the formation of vertical cavities (5 ) and (7), and the horizontal cavity (16), which when filled with reinforced or simple concrete, develops a stable concrete structure, with load capacity. When the channel is filled with concrete

(16), there is a smaller channel (17) that its function in the vertical development of walls is, to receive the lower part (3) of another block, which together will form a padlock between the two pieces. The lower part (3) is formed by a vertical downward movement between the lateral faces, of the internal walls (9), (10), (11), (12), (13) and (14) between the lateral faces (4). The front part of the block has two vertical projections (6), which when connected to the back (8) of another block, will form a vertical cavity for fixing the blocks in horizontal development and forming a cavity (7) , which is filled with concrete, eventually forming the structure of interleaved pieces, without concrete blind spots and without direct foam bridges. In the vertical projection (3) seen in Figure 7, the holes (18) are appreciated, that their function is to receive the projections (15), which are part of the vertical wall (11) and that adjust the placement of a block over another and prevent a horizontal movement between blocks.

The square arrangement between two blocks, gives rise to the formation of the piece T of Figure 9, which is to be drawn 3 cs for the stake 1 ad is an internal arrangement of 1 as vertical walls (9), (10 ), (11), (12), (13) and (14), which are the same as those in the block of Figure 8, and which form 1 as the same vrtical vities (5) and (7), and j together with the external walls (4), they shape the channel (16) and the horizontal padlock (17). In this piece, all the parts are similar to the block of figure 8, with the exception of the vertical cavity (19), which in this case is a square.

Now, when a horizontal development of blocks reaches a corner, it forms the block-corner piece of Figure 10, in which two external faces have been removed to denote the internal particularities that are exactly equal to those of the block of figure 8, with the exception of the corner itself, which develops a vertical hole, which when filled with concrete protects the internal arrangement of the vertical concrete elements to avoid concrete blind spots, in this case the protrusions do not appear (15 ) on the walls (11), this same horizontal development gives rise to the column-blocks, figure 13, figure 14 and figure 15 when a part of the block widens with thicker walls, they favor a vertical cavity (23), (24 ) and (25) that gives rise to a column. In the elements of figures 17, 18, 13, \ 4 and 15 the densities used are higher; when the horizontal development becomes curved, it gives rise to the curved block of Figure 16 in which the same vertical ducts (5) and (7) and the curved walls (26) of different radii appear. The use of the blocks described above develop a new structure, figure 19 with the horizontal beams (29) the ducts (30) and (32) and the separated and interwoven columns (31) with the characteristics set forth in the reinvidications.

In the horizontal development of the blocks, when there are openings of windows or doors, the block takes an arrangement that cuts the internal vertical walls as seen in Figure 12 in which the horizontally formed hollow is highlighted, which when filled with concrete reinforced, according to the corresponding structural calculation, ends up forming, in this case, a closing beam (21), which contains in its upper and lower part, all the elements, with all their characteristics of the blocks described in Figure 8. This block-enclosed piece is observed in Figure 11, in which a side face has been removed to observe the development of the internal vertical walls (8), (9), (10), (11), ( 12), (13) and (14), which together with the external walls (4), shape the vertical cavities (5) and (7) and the horizontal cavities (16) and (17). It is observed that the vertical walls being cut inside, give formation to the duct (21) and the lower part (22), which is similar to the part (3) of the block of Figure 8, when the block-enclosure ( 12) It is used as a foundation beam block (17) or block block (18), the lower part (22) disappears to form the lower closed part (33) that sits on ground or formwork. The ducts (27) and (28) are larger than the duct measures (21). The final structure of figure 19 formed by all the elements described ends up forming a stable framework, with a load capacity greater than any existing masonry wall, highlighting its decrease in mass with the advantage, therefore, of a decrease in foundation work and an improvement in its seismic capacity apart from the random capacity in thermal and acoustic insulation.

The invention relates to a simplified block of polyurethane or polystyrene foam, homogeneous and hollow, with internal walls structured among themselves, which do not need internal or external fittings to form intercalated horizontal and vertical cavities, which when filled with reinforced concrete or simple, they form an element with structural stability and load capacity, and when this block remains in the construction site, they form concrete walls with thermal and acoustic insulation.

At the upper, lower, front and rear ends, it contains homogeneous padlocks that interconnect the blocks horizontally and vertically, for the construction of concrete walls, thermally insulated. Foam blocks are similar to concrete blocks that have 3 measures, length, height and width (thickness) and that contain 2 or 3 vertical holes inside; the foam blocks differ in that they are longer, taller and of the same thickness, contain inside holes vertical in different figures, measures and quantities that depend on the density of the foam used, which are filled with reinforced concrete, that form small columns of low slenderness; the vertical holes in this example have a shape, plan view, of hollow T, the hollow T's are composed of 2 elements, one horizontal and one vertical, with its very short vertical element, the foam blocks in this example have 48 " long, 24 "tall and 6" thick, with 11 vertical T-shaped holes in two positions; the hollow T has a 5 "long x 1" tall rectangle on its horizontal element and its short vertical element , another horizontal rectangle 3 "long x 1" high. The 11 hollow T's contained in the block are arranged as follows: a hollow T in its normal position and a second inverted hollow T, joined at the bases of its short vertical elements, now, horizontally shifting the inverted T horizontally on its right axis of union of the two short elements, until the lower right corner of the T in normal position is 1 "from the upper left corner of the inverted T . The third T goes in the same position as the first but shifted to the right of the inverted T until its lower left corner of the element vertical is 1 "from the upper right corner of the vertical element of the inverted T, then follow the same procedure until you have 11 T's.

The length of the 11 (eleven) T's arranged as explained, will develop a distance of 45 "and the normal and inverted T's develop a height of 4"; a rectangle of 48 "x 6" is placed on the formation of the T's and there are 2 spaces of 1 "on the horizontal elements of the normal and inverted T's, in addition there are 2 spaces of 1 Vi at the ends of the line of T's, this is the block seen in plan in which all the spaces of the rectangle of 48 "x 6" that surround the T's, come to be the foam of injected or handmade polyurethane, or of expanded or extracted polystyrene, which forms the formwork to empty 11 columns without adding any different element for the structuring of the foam that in this case is homogeneous; in a view in front elevation of the block, a rectangle 6 "wide by 24" high is formed, they form a central part 4 "wide by 22" high and on their sides, two parts, one on each side 1 "wide, if these 3 parts have the same base, the 1" side parts protrude 2 " above the central part and a channel 4 "wide by 2" high is formed, then or 1 "the central part of 4" wide slides vertically down without moving the side walls of 1 ", the upper channel will increase to 4" wide by 3 "high and below it forms a projection of 1" below of the side walls. This projection of 1 "of foam that contains the vertical ducts in the form of a noimal and inverted T serves to insert in the upper channel of another block that is below, giving rise to the formation of a horizontal duct 48" long than at filling it with reinforced concrete will form a beam, at the time of emptying the beam, the T-shaped vertical ducts that formed small vertical columns with beams at their ends will also be filled with concrete.

The blocks of injected or handmade polyurethane foam, or of expanded or extracted polystyrene, in turn are manufactured in specific, closed and disassembled molds of iron, wood, plastic or sheet, which contain elements with various measures inside specific, and that the resulting products have different foam densities and different exterior measurements; inside they contain different amounts of ducts which in turn have different sizes and placements. Vertical ducts will be filled with hydraulic concrete which may be in different resistances depending on the design specification, and the ducts will have different measures in terms of length, width and height derived from the different densities used in the manufacture of the foam block.

The concrete filled ducts may be reinforced with corrugated rods in different resistances and diameters, resulting also from the structural calculation applied, these concrete filled ducts form small columns of reduced slenderness. The result is a new reinforced concrete structure, which has a good axial load capacity, which, together with the reinforcing steel, increases its defined structural capacity, and improved with respect to the materials currently used in walls, ceilings. b concrete blocks, 1 concrete bricks or mud blocks, cellular concrete, expanded perlite blocks or blocks of volcanic gravel that generally require a structure based on castles and enclosures running throughout its horizontal development. In the reinforced concrete structural walls resulting from the use of foams, the need for castles is canceled and the enclosures are only used in the clearings of the windows and doors.

The horizontal ducts are in turn filled with hydraulic concrete of the same resistance used in the columns, since the filling of horizontal ducts is executed simultaneously. The resulting concrete beams, in turn, will have a reinforcement of corrugated (or smooth) rods in different diameters that are also the result of the structural design calculation. The behavior resulting from the reinforcement of reinforced concrete columns and beams is stratigraphically superior to the existing walls mentioned, noting that in addition to the structural improvements mentioned, an "R" insulating capacity is obtained, far superior to any other obtained currently in construction projects and also in the formed wall will always find reinforced concrete when it comes to drilling its surface. It is also mentioned that for the vertical and horizontal union between blocks, no extra attachment is necessary because the design has foam parts that are homogeneous to the block and that serve to form padlocks in the upper and lower, front and rear parts of the block; not needing extraordinary parts for the construction of the foam block wall, since they act as locks when emptying the concrete inside the block. This detailed description of the invention of a simplified block of polyurethane or polystyrene foams, homogeneous and hollow, does not in any way attempt to limit the described characteristics, which were only presented as examples, although it includes all possible uses, In the same way, the interior development of 1 area between walls, which in the example described were formed by fat figures, which may vary to trapezoids, circular or elliptical sectors, capital letters I, but always keeping the parameters of Moment of Inertia, Areas of

Concrete Support, Volume of Concrete and Foam, that develops a stable structure, with load capacity and that ends up having all the scope of the reinvestments mentioned below.

Claims

CLAIMS Having described my invention sufficiently, I consider it as a novelty and therefore, claim as my exclusive property, what is contained in the following clauses:

1. Simplified block of polyurethane foam or polystyrene foam, homogeneous and hollow, characterized by the internal arrangement of its structured walls, which do not need interior or exterior fittings to form, together with the external walls, a series of horizontal cavities and an arrangement of vertical cavities in the form of a hollow uppercase letter T that can change to trapezoids, circular, elliptical or parabolic sectors, circles, rectangles, squares; Letter I uppercase hollow with a shorter base than the other, always alternating the arrangement of the figures to protect the condition of interleaved walls; which when filled with reinforced or simple concrete, result in an element with structural stability and load capacity, which does not allow concrete blind spots or direct foam bridges. Containing a projection in its lower part, formed by a vertical displacement below the internal walls between the external faces that end up forming a horizontal longitudinal padlock, when said projection is inserted, in the upper part of another block that has a channel throughout its upper horizontal length, due to the downward movement of the inner walls. Vertical projections on the front of the block, which when inserted in the back of another block containing the entrances, to form a padlock to develop a wall in the longitudinal direction, this padlock gives rise to a vertical cavity, which, together with the cavities of the internal walls and the above mentioned channel, when filled with reinforced or simple concrete, they develop a structural element with stability, load capacity. When said block remains in the construction site, it becomes part of a concrete wall with integral thermal insulation. The resulting blocks They have a rectangular shape that allows the structured formation of squares, crosses, T'es, block-enclosures, foundation beam blocks, trab blocks and column blocks, they also adopt the curved shape with different radii.

2. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized in that it is rectangular in shape with an internal arrangement of hollow capital T-shaped vertical cavities, which can change to trapezoids, circular sectors , elliptical or parabolic sectors always following the disposition of a normal and the next inverted figure, as well as a capital and hollow I with a shorter base than the other, always alternated in their arrangement.

3. Simplified block of polyurethane foam or polystyrene foam, homogeneous and hollow, as indicated in claim 1, characterized by the resulting structure, of reinforced or simple concrete, inside it cancels the construction of castles and enclosures run in the construction of loading or dividing walls.

4. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized in that the blocks can be manufactured by extrusion or expansion of the foam of polystyrene; with fixed or portable proportional pressure equipment or manual mixing of the components of the polyurethane foam in a mold that follows the specifications of the height, width, internal cavity measurements and the density of the foams used.

5. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized in that the blocks vary their vertical measurements according to the density of the foam.

6. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized by having a higher insulation capacity in smaller block thickness, as a result of the internal arrangement of the foams.

7. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized in that the structuring of the foams does not require additional fasteners.

8. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized in that they have connectors in their upper and lower parts, which define the placement of one block over another, avoiding horizontal sliding between two blocks

9. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized by the ability to be transformed into block-enclosure, block-foundation beam or block-lock with the single interior cut of a part of the vertical walls that gives rise to a horizontal hole that when filled with concrete creates a beam reinforced with rods.

10. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized in that it is a block that retains all its characteristics, with the difference that in its horizontal development it has a widening to form a column cavity with a larger cavity and thicker walls with varying foam densities, in order to form a foundation beam.

11. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized in that it can be assembled by hand using cutouts and foam plates, joined together using a hydraulic binder or a polyurethane adhesive, following always the specifications of internal distribution, measurements, thicknesses and densities of the foams.

12. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized in that it can be filled with concrete or any hydraulic binder, either reinforced or simple.

13. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized in that it can be coated on its outer faces with mixtures of concrete emptied in place, with the addition of anchor holes in the foam and wire clips that are embedded inside when filling the block.

14. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized by being able to develop curved walls in the use of retaining walls or tanks, with different radii and thicknesses without changes in accommodation specifications , measurements, thickness and densities of the foam.

15. Simplified block of polyurethane or polystyrene foam, homogeneous and hollow as indicated in claim 1, characterized in that the structure formed with all the elements described, ends up forming a stable framework, with the capacity to withstand vertical loads and higher horizontal loads to which any masonry wall can resist, highlighting its decrease in mass, consequently a decrease in foundation work and an improvement in its anti-seismic capacity, apart from the random capacity in thermal and acoustic insulation.