RS20230400A1 - Universal asymmetrical heterogeneous building block for rapid construction - Google Patents

Abstract

The universal asymmetric heterogeneous building block for rapid construction refers to the giter block formed by two segments, accumulation massive clay and insulation, which are designed to enable efficient energy accumulation and three times its storage capacity with equal consistency of the building structure and rapid construction through one phase. This was achieved by the fact that the body (1) of the block is shaped like a hollow modified cube whose sides (2, 3), base (4) and top (5) are flat surfaces, while the sides (6, 7) are profiled with vertical outlets (8, 9, 13, 14) and inlets (10, 11, 12, 15), where the partitions (17, 19, 23) formed tubular openings (16, 18, 20) filled with fillings (21) of insulating material. The block in question is made so that in the massive part of the block, the clay plate (22), a larger mass is concentrated on the back side, which is used for storage, i.e. energy accumulation, while the insulating part of the block on the front side is intended for thermal and acoustic insulation.

Description

UNIVERSAL ASYMMETRIC HETEROGENEOUS

BUILDING BLOCK FOR RAPID CONSTRUCTION

TECHNICAL FIELD

The subject of the invention generally falls within the field of construction, and specifically relates to a universal asymmetric heterogeneous building block made of clay and fill for rapid construction.

According to the International Patent Classification (IPC) Int.cl. 2022.01, the subject matter of the invention is classified and designated by the basic classification symbol E04C 1/40, which defines elements in the form of blocks or other shapes for parts of buildings made of various materials or stone with filling material or with insulating inserts, as well as by the secondary classification symbol E04C 1/41, which refers to elements in the form of blocks composed of insulating material and a supporting part made of stone-like material.

TECHNICAL PROBLEM

The technical problem solved by the present invention is the following: how to construct and produce a heterogeneous universal building block made of clay and insulating material, e.g. rock wool, asymmetric in terms of structure in relation to the longitudinal axis and formed of two segments, the accumulation massive clay and the insulation, which enables efficient energy accumulation and at least three times greater capacity for its storage compared to similar blocks, with equal consistency of the building structure and faster construction that takes place through one, instead of three or more phases most commonly used in classical construction today, through a system of at least five elements: load-bearing wall, thermal insulation, acoustic barrier, energy accumulation and vapor-permeable opaque partition, whereby its application results in greater load-bearing capacity of the internal surface, better and safer hanging of hanging parts attached to the internal surface of the walls, reduced operating costs for electricity and increased useful area of the building due to reduced thickness of the facade walls.

STATE OF THE ART

Energy efficiency today, at a time when the whole world is fighting for energy savings, is an important criterion for assessing the quality of a building. The most significant energy savings are achieved by good insulation of the building and careful selection of materials used during construction, which practically affects the cost of heating and cooling. In recent decades, in order to increase the thermal stability of the building, there has been a rapid development of thermal blocks, which have significantly improved the comfort of living, working and living. In addition to thermal properties, these blocks are also characterized by larger dimensions, so construction is faster and simpler with them, with less waste and a number of other additional advantages.

Today it is known that the best characteristics are exhibited by the so-called clay thermal blocks, which are therefore increasingly common in construction. Gitter blocks, as they are often called, are made of high-purity clay without artificial additives and are characterized by high compressive strength, fire resistance and the possibility of application for the production of thermal insulation, thermal barriers and acoustic barriers. By installing them in buildings, the cost of heating and cooling is reduced by more than 40%. In addition, clay blocks are long-lasting and do not require any maintenance. Today it is well known that the thermal conductivity coefficient (A value) for clay thermal blocks ranges from 0.2-0.40 W/<M>K, with the note that the lower this coefficient, the better the material is as a thermal insulator. Therefore, clay thermal blocks have up to 5.5 times better thermal insulation properties than concrete and about twice as good as solid brick.

A review of available domestic and foreign patent documentation found the following:

In the Chinese patent CN212613177U published on 2021-02-26 under the title "Energy-saving building block", a block is shown that is made of a clay expanded clay base plate, composed of multiple layers, wherein the first functional layer is formed on the outer side of the block, so that it contains a layer of anti-cracking mortar, followed by a layer of rigid foam polyurethane and an inorganic vitrified micro-granular layer, while the second functional layer is applied to the outer side of the first functional layer and consists of epoxy resin and polyurethane waterproof coating. According to the disclosed utility model, the clay expanded clay base plate is formed so that the properties of heat preservation, thermal insulation, sound insulation, moisture penetration resistance, fire resistance, impact resistance, frost resistance, etc. are enhanced by using clay. A layer consisting of anti-cracking mortar, a polyurethane rigid foam layer and an inorganic vitrified microlayer was also placed on the base plate; while a layer of epoxy resin primer and a layer of waterproof polyurethane were applied to the second functional layer. It is evident from the application of this utility model that the presented block, which is heterogeneous, does not solve the issue of heat accumulation and preservation and is therefore not suitable for use in environments with pronounced temperature extremes.

The technical solution of a large-format clay block manufactured by Wienergberger, under the commercial name Porotherm IzoProfi, is known, which is heterogeneous because it has thermal insulation filling in vertical cavities, but does not have a massive inner wall, i.e. it has fewer possibilities for heat accumulation.

A review of the propaganda material also found a large-format energy clay block manufactured by "Mladost" doo from Serbia, which has vertical cavities, but without filling and without a pronounced part for energy storage. In addition, this block has a much larger number of cavities, which is a feature of other manufacturers, e.g. Klima Blok, Zorka, Šabac, Termo Blok, Univerzuma from Aranđelovac, etc. The feature of these blocks is that they are all symmetrical in terms of mass distribution, while the newly designed block is asymmetrical.

It is surprising for the inventor that despite a careful search of available patent and non-patent documentation, no technical solution relevant to the subject invention was found.

EXHIBITION OF THE ESSENCE OF THE INVENTION

The essence of the invention is that, according to the inventor's idea, a universal heterogeneous asymmetric building block has been constructed, the heterogeneity of which is reflected in the combination of clay and quick-build filling made of insulating material, e.g. rock wool, while the asymmetry is achieved by the structure of the accumulation mass in relation to the longitudinal axis, designed so that the massive part of the block in which the greater mass is concentrated, i.e. the part dominated by clay, serves for storage, i.e. accumulation of energy, while the insulating part of the block is intended for thermal and acoustic insulation.

The essence of the invention is that the combination of the clay outer edges of the block and the partition walls forms vertically arranged tubular openings, directed towards the bearing plane, symmetrically spaced in axial parallel rows and filled with insulating material, arranged so as to form two functional parts, whereby the massive part of the block, the width of which is at least 24% of the total width of the side, serves to store energy and represents the inner, i.e. rear side of the block, which is in contact with the space in which thermal comfort is maintained, while the second insulating part has the function of a thermal barrier and forms the outer side of the non-transparent partition, i.e. the front side of the block, with the note that with increasing width of the block, the thickness of the part for storing energy also increases.

The essence of the invention is also that the block according to the invention has at least three times the energy storage capacity compared to other similar available products, i.e. it enables the accumulation of 74.5 kJ/m<2>K of energy compared to 18.2 kJ/m<2>K, which is the estimated accumulative capacity of similar thermoblocks.

The novelty of the invention is also reflected in the fact that the subject block has a greater load-bearing capacity of the inner surface due to the greater thickness of the clay part on the inner side.

What represents a significant essential difference compared to previously known technical solutions is that the construction of a wall with a block according to the invention takes place through only one phase in which at least five elements are implemented: a load-bearing wall, thermal insulation, acoustic barrier, energy accumulator and vapor-permeable opaque partition, which makes it significantly more economical and allows for significant savings even compared to masonry that involves two separate phases, i.e. construction of a load-bearing wall (phase 1) and construction of a heat accumulator (phase 2), with the note that the application of the subject block implies a solution according to which the heat accumulator becomes part of the building structure.

The newly constructed building block, according to this invention, has several advantages over previously known technical solutions, the most important of which are listed as follows:

- reduced construction time due to a smaller number of phases by approximately 2-8%; - lower construction costs by approximately 4-5% due to a smaller number of working hours of engaged workers and a shorter time of using scaffolding as a necessary element during construction;

- for the same dimensions of the building, a 4.4% larger net usable area is obtained due to the reduced thickness of the facade walls, with the same heat transfer coefficient of about 0.3 W<M2>K being obtained with a 25 cm thick concrete block plastered on both sides compared to structures built from a standard 25 cm thick block and additional thermal insulation in the form of a 12 cm thick demit facade;

- lower operating costs for electricity by 7-10% due to energy storage during times of lower electricity tariffs.

SHORT DESCRIPTION OF THE DRAWING IMAGE

For the purpose of easier understanding of the invention, the inventor refers to the attached drawings of the application and where:

- Figure 1 is a schematic representation of a wall made of the subject universal asymmetric heterogeneous blocks in axonometry;

- Figure 2 is a schematic representation of the subject building block in axonometric view from above;

- Figure 3 is a schematic view of the subject building block from below;

- Figure 4 is a schematic representation of the subject building block in front view;

- Figure 5 is a schematic view of the subject building block in rear view;

- Figure 6 is a schematic view of the subject building block as viewed from one of the shorter sides;

- Figure 7 is a schematic representation of the subject building block as viewed from the other shorter side.

- Figure 8 is a schematic representation of temperature oscillations on the inner surface of a wall without thermal insulation;

- Figure 9 is a schematic representation of temperature oscillations on the inner surface of a wall with thermal insulation on the outer surface of the facade wall;

- Figure 10 is a schematic representation of temperature oscillations on the inner surface of the wall when thermal insulation is performed inside the facade block;

- Figure 11 is a schematic representation of temperature oscillations on the inner surface of the wall in the case of a facade wall with the subject block.

DETAILED DESCRIPTION OF THE INVENTION

In order to construct a thermoblock with improved technological characteristics, primarily in order to expand the possibilities of application to areas with pronounced cold and warm climatic conditions, while reducing production costs and increasing the speed of construction, and making it more economically competitive, easier to manipulate and transport, the inventor decided to construct a universal asymmetric heterogeneous building block made of clay and fill, the method of application of which, i.e. positioning during construction, functionally optimizes the constructed structure by placing either a massive, accumulation part of the block on the front side or an opposite part in which the insulating material is the dominant structure.

As can be seen from Figures 1 and 2 of the attached drawing, the body 1 of the block is designed in the form of a hollow modified square, the longer side sides 2, 3, as well as the base 4 and the upper side 5 are designed as flat surfaces, while the shorter side sides 6, 7 are profiled in such a way that the side side 6 consists of laterally connected vertical protrusions 8, 9 and recesses 10, 11, while on the other side side 7, recesses 12, 15 are designed and laterally interconnected by recesses 13, 14. All recesses and protrusions are flat, perpendicular to the bearing surface and have a rectangular appearance in vertical section.

This block construction, with vertical inlets and outlets arranged alternately on the shorter sides, enables faster and easier construction of load-bearing, retaining, sandwich, fire-prevention walls, partitions, etc., whereby during masonry, the blocks are placed so that the outlets 8, 9 fit into the outlets 12, 15, while the outlets 13, 14 fit into the outlets 10, 11. This positioning of the blocks, i.e. their horizontal connection in the same direction with minimal gaps, results in a consistent wall whose thickness is characterized by the dimensions: length and width of the body 1 of the block. As can be seen from Figures 2 and 3 of the drawing, each block has vertical tubular openings 16, 18, 20 directed to the bearing plane, whereby between the side inlet 12 and the outlet 8 there are equally spaced, symmetrically positioned tubular openings 16 whose cross-section has the appearance of a rectangle, on one side limited by the longer side 2, and on the other side separated by a vertical partition 17 from symmetrically arranged tubular openings 18 of rectangular cross-section, equally spaced from each other and also separated by a partition 19 from tubular openings 20 of rectangular cross-section arranged between the vertical inlet 15 and the vertical outlet 9. The rear part of the block is made of a compact clay plate 22 bordered by the longer side 3, the side edges that form the vertical inlet 11 and outlet 14 and tubular openings 20. The heterogeneity of the block is reflected in the fact that in the body 1, with longer side sides 2, 3, shorter side sides 6, 7, axial partitions 17, 19 and partitions 23, made of clay, tubular openings 16, 18, 20 are formed, filled with fillings 21 of vapor-permeable insulating material, which simultaneously represents a thermal and acoustic barrier. In order to prove the feasibility of the invention, rock wool is shown as an insulating material, with the note that other vapor-permeable materials can be used instead, which prevent water penetration and at the same time enable efficient removal of water vapor from the blocks. Based on this, it can be seen that, unlike the most commonly used blocks available on the market, which are exclusively symmetrical in relation to all three axes, the block in question is made asymmetrically in terms of mass structure in relation to the longitudinal axis. The consequence of this block design is that the massive part of the block is the part in which the greater mass is concentrated, i.e. the part in which clay dominates, bearing in mind that the main role of mass is storage, i.e. accumulation of energy.

When deciding on this type of construction of the subject block, the inventor proceeded from the fact that the surface mass (kg/m<2>) is determined as the product of the thickness of the accumulation layer and its density (kg/m<3>), therefore from the fact that for the same dimensions of the clay block, the thickness of the inner side of the block/wall with the installation of the block according to the invention is 5-6 times greater than in walls made of standard blocks available on the market. When the surface mass (kg/m<2>) is multiplied by the specific heat of a given material (J/kgK), the accumulative capacity of the material (J/m<2>K) is obtained, i.e. in this case, the clay part of the block, so this distribution of the clay part of the structure achieves more efficient heat accumulation, i.e. optimal energy storage on the inside of the masonry structure, with the note that the density of clay is about 20 times greater than the density of insulating materials.

It should also be emphasized that the massive part of the block, i.e. the clay plate 22, made of clay, is oriented along the rear longer side 3 of the body 1, i.e. the side that is in contact with the space in which thermal comfort is maintained and is intended for energy storage, while the other insulating part of the block, which has the function of a thermal barrier, represents the outer side of the non-transparent partition. This means that the part of the block with little clay and a lot of insulation is oriented towards the front side of the body 1, while on the contrary, on the rear longer side 3 of the block there is a part with significantly more clay and a reduced proportion of insulation. In this way, the segment for thermal and sound protection is "unloaded" with clay material, i.e. a certain amount of clay that in other products is located in the central part of the block and towards the outer surface, is redistributed into the energy storage segment. In that part, the insulation material, i.e. rock wool, occupies a larger space, and the clay is kept in a minimal amount, i.e. in an amount that provides the necessary mechanical strength of the product.

The thermal stability of the subject block is illustrated in the graphs, Figures 8-11, from which, for example, the temperature oscillations on the inner surface of the wall show the dependence on the distribution of the accumulation layer and the insulation layer in the block. The property of building structures to maintain the most constant temperature on the inner surface represents their thermal stability, and it is known that greater thermal stability contributes to greater thermal comfort, because the effects of a cold wall in winter, or a warm wall in summer, are eliminated. Namely, the large thermal mass on the inner surface of the facade wall increases the thermal inertia of the inner surface of the wall, which "calms down" the oscillations of the outside air temperature on the inner surface of the wall, which is clearly seen in Figures 8-11. Precisely for this reason, the subject block provides the best thermal stability of the building structure.

The blocks constructed in this way, whose mechanical strength and dimensions are defined by the new distribution of clay in the structure, allow construction to take place in only one phase, instead of using the five-phase or three-phase system that is widely used today. This means that the use of such blocks achieves the function of a load-bearing wall, thermal insulation, acoustic barrier, energy accumulator and vapor-permeable opaque partition, and it should be emphasized that with the construction of the block in question, the heat accumulator (energy storage) becomes part of the opaque facade structure.

The block, according to the invention, has at least three times the energy storage capacity of other available products, i.e. it accumulates 74.5 kJ/m<2>K of energy compared to 18.2 kJ/m<2>K, the estimated accumulative capacity of similar thermal blocks. The advantage of using the subject block is also reflected in the greater load-bearing capacity of the inner surface due to the greater thickness of the clay part on the inner side, which, among other things, achieves better securing of hanging furniture parts that are attached to the inner surface of the walls.

To prove the feasibility of the invention, a technological process for producing a block is presented, which consists of the following:

Primary processing begins in box feeders, from which the raw material falls onto plate conveyors, which are used to transport it to wheel mills. In wheel mills, wet grinding is carried out by crushing and pouring the clay with rollers onto a perforated tread plate and partial homogenization of the raw material. The clay is extruded through perforations and reaches the plate feeders of the wheel mills and from there falls onto plate conveyors. The plate conveyor transports the clay to coarse differential rollers in which grinding is carried out to a maximum granulation of 2-3 mm. Final preparatory processing takes place in the so-called fine mill, in which the raw material dimension is finalized to a granulation of 1-1.2 mm. The clay in the final granulation reaches the double-sided spreader via a rubber conveyor system, which spreads the clay and fills the basin lengthwise with a reversible stroke. In addition to evenly filling the basin with a reversible stroke forward and backward, the spreader also homogenizes the raw material by spreading it along the length and width of the basin. The clay deposited in the basin enables the smooth operation of the factory throughout the year, regardless of weather conditions. The clay in the basin ages and thus acquires the necessary properties for fine shaping (structure relaxation, plasticity, uniform humidity, moisture penetration into the fine structure of the clay mass, etc.). The production technology requires that the raw material ages after primary processing.

From the basin, the clay is extracted using a loading shovel and transported to a box feeder for secondary processing. The clay block pressing process is preceded by secondary processing of the raw material, in which the processed clay is passed through a fine mill once more to remove the so-called "slag", as a result of the aging of the raw material. The raw material size remains at 1-1.2 mm. The clay is transported by conveyors to the vacuum press mixer, water is added for shaping, and then it is intensively mixed and pressed on the screws that compress it into the mixer cylinder, at the outlet of which knives are placed. The knives cut the clay, which falls into the vacuum chamber in the form of "noodles". Captured by the screws from the vacuum chamber, the clay is pressed into the press cylinder. The processed raw material is pushed into the tool by a screw drive and extruded through the nozzle on the press head in the form of a clay body of the desired cross-section. The extrusion pressure is 20-25 bar. The shaped clay structure is accepted by a horizontal conveyor with rollers where cutting is performed to the desired height of the finished product. The height of the product is determined in advance by the prepared distance of the steel wires on the cutting device. After the cutting phase and forming the shape of the finished product in all three dimensions, the raw products are briefly stored in a warehouse, from which, after collecting an adequate number of products, they are transported to the dryer.

Drying is the most sensitive phase, because the construction of the product in question, due to its asymmetry, provides for an innovative solution that allows the drying process to be carried out in a way that ensures the product maintains a stable structure, without deformations or cracks.

The drying process takes place in three stages:

- heating phase in a humid atmosphere T=45-50° C, relative humidity up to 80%, process duration up to ten times;

- evaporation phase by introducing hot air T=100-150° C, with variable opening of the regulation valve for the flow of hot air, process duration 5-7 times;

- the final drying phase, reducing the moisture content to 16-17%, is carried out with maximum flow of warm air.

The dried products are transported to the dried products warehouse, from where they are stacked on tunnel kiln wagons according to a precisely defined schedule, through which they move along the track at a predefined speed.

The baking process takes place in three stages:

- the preheating phase includes the wagons up to the first firing group in which the combustion gases from the firing zone move towards the flue gas fan and exchange heat along the way, so that the products reach the first firing group with a temperature of 600-650° C;

- the firing phase takes place through the direct action of the burner, according to whose arrangement the arrangement of parts on the transport wagon is defined, whereby the firing temperature can be up to 1000° C;

- the cooling phase occurs after the firing phase, exiting the last burner group. The accumulated heat in the products and on the transport wagons is directed towards the dryer by controlled air blowing, in order to make the production process as efficient as possible.

After the cooling process and stacking of products on pallets are completed, they are transported to the section of the final phase of block production where the filling of vapor-permeable insulation material is added. The pallets, each containing one product per height, pass along the track past the workstations where the pre-prepared insulation filling of the correct dimensions is inserted into the vertical cavities of the clay block, thus completing the process of making the block in question.

After inserting the insulating material into the vertical cavities of the clay block, a visual inspection of the finished product is carried out, then the finished products are packed on pallets, wrapped with stretch film and sent to the finished products warehouse.

METHOD OF INDUSTRIAL OR OTHER APPLICATION OF THE INVENTION

Industrial or other method of obtaining a universal asymmetric heterogeneous building block made of clay and fill, according to this invention, is absolutely possible in enterprises for the production of construction equipment, and even in well-equipped construction workshops, and its application is recommended when constructing facilities where it is necessary to achieve rapid construction with significant savings in energy and material. When making the blocks, the existing known technology for the production of brick clay blocks with vertical cavities is used.

The subject invention is suitable for serial production based on workshop documentation that experts in the subject field can produce using the description and drawings from the subject patent application for the invention.

It should be noted that testing the efficiency of the block in question on prototypes showed excellent results not only when used as an element for building a wall, but also as a product that, in conjunction with mechanical installations, meets the requirements for efficient energy storage in wall panels, noting that it is also compatible with low-temperature wall heating and high-temperature wall cooling installations as imperatives for the use of heat pumps, i.e. highly efficient devices that use renewable energy sources.

Claims (5)

PATENT CLAIMS 1. Universal asymmetric heterogeneous building block for rapid construction, characterized in that the body (1) of the block is made in the form of a hollow modified square whose longer side sides (2, 3), base (4) and upper side (5) are made as flat surfaces, while the shorter side sides (6, 7) are profiled in such a way that the side side (6) consists of laterally connected vertical protrusions (8, 9) and recesses (10, 11), while on the other side side (7) recesses (12, 15) are made laterally interconnected by protrusions (13, 14), and in that a clay plate (22) is positioned on the rear part of the body (1), while tubular openings (16, 18, 20) are arranged in parallel axially on its front part. 2. Universal asymmetric heterogeneous building block for rapid construction, according to claim 1, characterized in that the clay plate (22) is, on one side, bordered by a rear longer side (3), side edges forming a vertical inlet (11) and outlet (14), and on the other side by tubular openings (20). 3. Universal asymmetric heterogeneous building block for rapid construction, according to claim 1, characterized in that the vertical tubular openings (16, 18, 20) are perpendicular to the bearing plane, whereby between the lateral inlet (12) and the outlet (8) there are mutually equally spaced, symmetrically positioned tubular openings (16) whose cross-sections have the appearance of a rectangle, on one side limited by a longer side (2) and on the other by a vertical partition (17) separated from three symmetrically arranged tubular openings (18) of rectangular cross-section, mutually equally spaced and separated by a partition (19) from four tubular openings (20) of rectangular cross-section axially arranged between the vertical inlet (15) and the vertical outlet (9). 4. Application of a universal asymmetric heterogeneous building block for rapid construction, characterized by the fact that the construction of the wall takes place in only one phase in which all five elements are implemented: load-bearing wall, thermal insulation, acoustic barrier, energy accumulator and vapor-permeable opaque partition. 5. Application of a universal asymmetric heterogeneous building block for rapid construction, according to claim 1, characterized in that the massive rear part of the block, consisting of a clay slab (22), is oriented towards the inner side of the structure, while the insulating part of the block, consisting of tubular openings (16, 18, 20) with fillings (21) of insulating material, is oriented towards the outer side of the masonry structure.