GB2540619A

GB2540619A - Monolithic building block

Info

Publication number: GB2540619A
Application number: GB1513077.6A
Authority: GB
Inventors: Fraimovich Semeon; Dvorkin Dmitry; Gal Erez; Pearlmutter David
Original assignee: Termokir Ind (1980) Ltd; BG Negev Technologies and Applications Ltd
Current assignee: Termokir Ind (1980) Ltd; BG Negev Technologies and Applications Ltd
Priority date: 2015-07-24
Filing date: 2015-07-24
Publication date: 2017-01-25
Also published as: GB201513077D0; WO2017017586A1

Abstract

A monolithic building block (10) includes a light phase (18) and a heavy phase (16), and has a density gradient along at least one direction of the block (10). A differential density between two spaced slices of the block taken in the same direction may be 300kg per cubic meter. The block may have different compressive strength in the two slices, with a ratio of at least 3:1. Thermal conductivity of one of the slices may be at most 0.36W/mK ands a thermal mass ratio of the slices may be at least 2:1. The block may include light aggregates selected from, polystyrene, hemp, cork, expanded glass, light expanded clay aggregate, pumice, perlite, scoria and vermiculite. The clock may include heavy aggregates selected from sand and crushed stone. The block may be moulded from slurry which is vibrated to stratify the aggregates.

Description

MONOLITHIC BUILDING BLOCK

FIELD OF THE INVENTION

The present invention relates to monolithic building blocks, and to methods of producing and using such building blocks.

SUMMARY OF THE INVENTION

The present invention relates to building blocks including two portions having different thermal characteristics, and to methods of producing and using such building structures.

In accordance with an aspect of teachings herein, there is provided a monolithic building block, comprising: (a) a first aggregate material; and (b) a second aggregate material; said first aggregate material and said second aggregate material embedded within a cementitious matrix to form the monolithic building block; a first cross-sectional slice of the block, taken in a first direction, having a first average density; a second cross-sectional slice of the block, taken in said first direction, having a second average density; the block having at least one of the following structural properties: (1) a differential density between said first and second cross-sectional slices is at least 300 kg/m^; (2) a thermal conductivity of said second cross-sectional slice is at most 0.2 W/(m*K); and (3) a thermal mass ratio of said first and second cross-sectional slices, per unit volume, is at least 2:1.

In accordance with an aspect of teachings herein, there is provided a building block, comprising (a) a cementitious matrix; (b) a first phase; and (c) a second phase; said first phase including at least a first aggregate material, said aggregate material and said second phase disposed within said cementitious matrix to form the building block; wherein a first cross-sectional slice of the block, taken in a first direction, has a first average density, pi; wherein a second cross-sectional slice of the block, taken in said first direction, has a second average density, pi; the building block having at least one of the following structural properties: (1) a differential density (pi - pi) between said first and second cross-sectional slices is at least 300 kg/m^; (2) a thermal conductivity of said second cross-sectional slice is at most 0.36 W/(m*K); and (3) a thermal mass ratio of said first and second cross-sectional slices, per unit volume, is at least 2:1.

In accordance with an aspect of teachings herein, there is provided a monolithic building block, comprising: (a) a cementitious matrix; (b) a first phase; and (c) a second phase; said first phase including at least a first aggregate material, said aggregate material and said second phase disposed within said cementitious matrix to form the monolithic building block; wherein a first cross-sectional slice of the block, taken in a first direetion, has a first average density, pi; wherein a second cross-sectional slice of the block, taken in said first direction, has a second average density, pi; the monolithic building block having at least one of the following structural properties: (1) a differential density (pi - pi) between said first and second cross-sectional slices is at least 300 kg/m^; (2) a thermal conductivity of said second cross-sectional slice is at most 0.36 W/(m*K); and (3) a thermal mass ratio of said first and second cross-sectional slices, per unit volume, is at least 2:1.

In accordance with an aspect of teachings herein, there is provided a method of producing a monolithic building block, the method comprising: (a) introducing a first aggregate material, a light phase, with respect to said first aggregate material, a cementitious material, and an aqueous liquid, to a vessel, to form a slurry; (b) vibrating said slurry to effect at least a partial stratification of said first aggregate material and said light phase, within said slurry; (c) setting slurry within a mold, to form a set block; and (d) removing said set block from said mold.

According to further features in the described preferred embodiments, the light phase includes a second aggregate material.

According to still further features in the described preferred embodiments, the second cross-sectional slice has a compressive strength, along said first direction, of at least 0.5 MPa, at least 0.75MPa, at least 1 MPa, at least l.SMPa, at least 2.5MPa, or at least 4MPa, and at most 15MPa, at most 12 MPa, at most 10 MPa, at most 8 MPa, or at most 6 MPa.

According to still further features in the described preferred embodiments, a compressive strength ratio of said first and second cross-sectional slices, measured along said first direction, being at least 3:1, at least 5:1, at least 10:1, at least 20:1, at least 50:1, or at least 100:1, and optionally, at most 1000:1, at most 700:1, at most 500:1, at most 300:1, at most 200:1, at most 150:1, or at most 120:1.

According to still further features in the described preferred embodiments, the thermal conductivity of said second cross-sectional slice is at most 0.32 W/(m*K), at most 0.28 W/(m*K), at most 0.25 W/(m*K), at most 0.22 W/(m*K), at most 0.20 W/(m*K), at most 0.18 W/(m*K), or at most 0.15 W/(m«K).

According to still further features in the described preferred embodiments, the thermal conductivity of said second cross-sectional slice is at least 0.03 W/(m*K), at least 0.07 W/(m*K), at least 0.10 W/(m*K), at least 0.12 W/(m*K), or at least 0.14 W/(m*K).

According to still further features in the described preferred embodiments, a thermal conductivity ratio between said first and said second cross-sectional slices is within a range of 0.03 to 0.25.

According to still further features in the described preferred embodiments, the differential density between said first and second cross-sectional slices is at least 325 kg/m^ at least 350 kg/m^ at least 400 kg/m^ at least 500 kg/m^ at least 600 kg/m^, at least 800 kg/m^, at least 1000 kg/m^, at least 1200 kg/m^, at least 1400 kg/m^, at least 1600 kg/m^, at least 1800 kg/m^, or at least 2000 kg/m^

According to still further features in the described preferred embodiments, the differential density between said first and second cross-sectional slices is at most 3000 kg/m^, at most 2700 kg/m^ at most 2400 kg/m^, or at most 2200 kg/m^

According to still further features in the described preferred embodiments, the second phase includes a second aggregate material, said second aggregate material optionally including, or mainly including, particles selected from the group consisting of polystyrene, hemp, cork, expanded glass, light expanded clay aggregate (LECA), pumice, pearlite, scoria, and vermiculite.

According to still further features in the described preferred embodiments, the first aggregate material includes, or mainly includes, particles selected from the group consisting of sand and crushed stone.

According to still further features in the described preferred embodiments, a weight ratio of said first aggregate material to said second aggregate material is within a range of 5:1 to 1000:1, 10:1 to 500:1, or 20:1 to 500:1.

According to still further features in the described preferred embodiments, the thermal mass ratio is at least 2:1, at least 4:1, or at least 10:1.

According to still further features in the described preferred embodiments, the thermal mass ratio is at most 16:1, at most 14:1, or at most 12:1.

According to still further features in the described preferred embodiments, the thermal mass ratio is within a range of 2:1 to 16:1, 3:1 to 15:1, or 5:1 to 15:1.

According to still further features in the described preferred embodiments, a void fraction within the block is at most 0.65, at most 0.55, at most 0.50, or at most 0.4.

According to still further features in the described preferred embodiments, a plurality of the monolithic building blocks includes at least a first monolithic building block, and a second monolithic building block rigidly attached thereto.

According to still further features in the described preferred embodiments, the plurality of monolithic building blocks forms at least a portion of a wall of a building.

According to still further features in the described preferred embodiments, the plurality of monolithic building blocks forms at least a portion of a ceiling.

BRIEF DESCRIPTION OF THE FIGURES

The foregoing discussion will be understood more readily from the following detailed description of the invention, when taken in conjunction with the accompanying Figures, in which:

Figure 1A is a perspective view of a schematic monolithic building block, according to one aspect of the present invention;

Figures IB, 1C, and ID are cross-sectional views of the monolithic building block of Figure lA, taken along section lines IB-IB, IC-IC, and ID-ID in Figure lA, respectively;

Figure 2 is a flow chart illustration of a method for fabrication of a monolithic building structure as shown in Figures lA - ID, according to an aspect of the present invention;

Figure 3 is a cross-sectional view of a monolithic building block according to one embodiment of the present invention, showing the segregation of light aggregate and heavy aggregate along a length thereof; and

Figure 4 is a cross-sectional view of a monolithic building block according to another embodiment of the present invention, as in Figure 3, but in which the light phase is largely made up of gas-containing voids.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The principles of the inventive building structure and the inventive methods of producing and for using such a building structure, may be better understood with reference to the drawings and the accompanying description.

Before explaining at least one embodiment of the invention in detail, it is to be imderstood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

Reference is now made to Figure lA, which is a perspective view of a monolithic building block 10 according to one aspect of the present invention, and to Figures IB, 1C, and ID, which are cross-sectional views of the monolithic building block 10 of Figure lA, taken along section lines IB-IB, IC-IC, and ID-ID in Figure lA, respectively.

As seen in Figures lA to ID, a monolithic building block 10 according to the present invention includes a composite structural slab 12 comprising a cementitious matrix 14, having embedded therein a first phase, which may include a first aggregate material 16. Embedded within cementitious matrix 14 may be a second phase, which may include a second aggregate material 18. Alternatively or additionally, the second phase may include a gas, typically air, such as void volumes or bubbles 19. The second phase may have an appreciably lower specific gravity with respect to the first phase.

The dimensions of the block are typically at least 10cm length by 10cm width by 10cm height. More typically, the length is at least 12cm, at least 15cm, at least 18cm, at least 20cm, at least 22cm, or at least 25cm. The length may be within a range of 10-100cm, 10-80cm, 10-60cm, 10-50cm, or 10-40cm. The height and width may be within a range of 10-50cm, 10-40cm, 10-35cm, or 10-30cm. The length-to-width ratio and length-to-height ratio may be within a range of 1:1 to 6:1, 1:1 to 5:1, 1:1 to 4:1, 1:1 to 3:1, 1.4:1 to 6:1, 1.4:1 to 4:1, 1.7:1 to 6:1, or 1.7:1 to 4:1.

The cementitious matrix or binder may include, mainly (i.e., >50%, by weight) include, or consist essentially of: Ordinary Portland Cement (OPC), calcium aluminate cement, calcium sulfo-aluminate (CSA) cement, lime, hydraulic lime, gypsum, sorel (magnesia) cement, water glass (sodium silicate), and geopolymer cement.

In some embodiments, the first aggregate material 16 comprises particles selected from the group consisting of sand, crushed stone, fine stone, or stone pieces, barite, various carbides, nitrides, fine or crushed ceramics, or other aggregate materials that will be known to those of skill in the art. Typically, such aggregate materials have a specific gravity of at least 2000 kg/m^, and/or a bulk density of at least 1200 kg/m^r 1400 kg/m^

In some embodiments, the optional second aggregate material 18 comprises particles selected from the group consisting of polystyrene, hemp, cork, polyurethane, expanded glass, light expanded clay aggregate (LECA), pumice, pearlite, scoria, and vermiculite or other light aggregate materials that will be known to those of skill in the art. Typically, such aggregate materials have a specific gravity of at most 1000 kg/m^, and more typically, at most 800 kg/m^, at most 600 kg/m^, at most 400 kg/m^, at most 300 kg/m^, at most 200 kg/m^, or at most 150 kg/m^. For those materials having a specific gravity well exceeding that of polystyrene, the segregation efficiency, under identical conditions, may be somewhat compromised. However, by increasing the vibration time, increasing the flowabihty (e.g., increasing the water fraction), and/or reducing the volume fraction of heavy aggregate, the segregation efficiency may be improved.

In some embodiments, block 10 may have a void fraction therewithin, the void fraction including a plurality of void volumes 19. Typically, the void fraction, by volume, is at least 0.05, at least 0.20, or at least 0.30. Typically, the void fraction, by volume, is at most 0.65, at most 0.55, at most 0.50, at most 0.45, or at most 0.35.

As seen with particular clarity in Figure IB, the first aggregate material 16 and the second aggregate material 18 within cementitious matrix 14 are differentiated along the length L of block 10, thereby forming first and second portions or slices of the block, indicated by reference numerals 20 and 22, respectively.

Figure 1C shows a cross-section of monolithic building block 10 within first portion 20, whereas Figure ID shows a cross-section of monolithic building block 10 within second portion 22. As seen in Figure 1C, the first portion 20, which is designed to face the interior of a building structure using blocks 10, includes mostly particles of the first aggregate material 16, and relatively few, if any, particles of the second aggregate material 18. Conversely, as seen in Figure ID, the second portion 22, which is designed to face the exterior of a building structure using blocks 10, includes mostly particles of the second aggregate material 18, and few, if any, particles of the first aggregate material 16. As such, first portion 20 of block 10 has a first average density or specific gravity, and second portion 22 of block 10 has a second average density or specific gravity. Typically, block 10 and first and second portions 20 and 22 may be characterized by at least one of a differential density (or specific gravity) between the first and second portions, a volumetric heat capacity ratio of the first and second portions, and a thermal resistivity of the first and second portions.

It should be emphasized that first and second portions 20 and 22 may be first and second cross-sectional slices of the block, taken in the same direction. These slices may be adjacent or non-adjacent. Together, the slices may constitute an entire dimension (typically length) of the block, or a portion thereof

As used herein in the specification and in the claims section that follows, the term “volumetric heat capacity” refers to the volume-specific heat capacity. Volumetric heat capacity has units of thermal energy divided by the product of temperature and volume, and in SI units, J/(m^ °K).

As used herein in the specification and in the claims section that follows, the term “thermal mass” refers to the volume of the constructive element (block, block portion, or a construction material used to produce such a block) multiplied by the volumetric heat capacity.

In some embodiments, the differential density between the first portion 20 and the second portion 22 is within a range of 350 to 3500 kg/m^, 500 to 3500 kg/m^, 650 to 3500 kg/m^, 800 to 3500 kg/m^, 1000 to 3500 kg/m^, 1200 to 3500 kg/m^, 1400 to 3500 kg/m^, or 1600 to 3500 kg/m^. More typically, this differential density is within a range of 800 to 2500 kg/m^, 800 to 2200 kg/m^, 800 to 2000 kg/m^, 800 to 1800 kg/m^, 800 to 1600 kg/m^, 1000 to 2500 kg/m^, or 1200 to 2500 kg/m^.

In some embodiments, the differential density between the first portion 20 and the second portion 22 is at least 300 kg/m^. In some embodiments, the differential density between first portion 20 and second portion 22 is at least 350 kg/m^, at least 400 kg/m^, at least 500 kg/m^, at least 600 kg/m^, at least 800 kg/m^, at least 1000 kg/m^, at least 1200 kg/m^, at least 1400 kg/m^, at least 1600 kg/m^, at least 1800 kg/m^, or at least 2000 kg/m^.

In some embodiments, the differential density between the first portion 20 and the second portion 22 is at most 3000 kg/m^, at most 2700 kg/m^, at most 2400 kg/m^, or at most 2200 kg/m^.

In some embodiments, the thermal conductivity of the second portion 22 is at most 0.5 W/(m*K). In some embodiments, the thermal conductivity of the second portion 22 is at most 0.48 W/(m*K), at most 0.45 W/(m*K), at most 0.40 W/(m*K), at most 0.35 W/(m*K), at most 0.30 W/(m»K), at most 0.25 W/(m*K), at most 0.20 W/(m*K), at most 0.15 W/(m*K), at most 0.12 W/(m*K), or at most 0.10 W/(m*K). In some embodiments, the thermal conductivity of the second portion 22 is at least 0.05 W/(m*K), at least 0.07 W/(m*K), at least 0.10 W/(m*K), at least 0.15 W/(m*K), or at least 0.20 W/(m«K).

In some embodiments, the thermal conductivity ratio between the first portion 20 and the second portion 22 is at most 0.3:1, at most 0.25:1, at most 0.2:1, at most 0.15:1, at most 0.1:1, at most 0.07:1, or at most 0.05:1. This thermal conductivity ratio may be at least 0.02, at least 0.025, at least 0.03, at least 0.035, at least 0.04, or at least 0.045. Typically, the thermal conductivity ratio is within a range of 0.03 to 0.25, 0.03 to 0.20, or 0.05 to 0.20.

The monolithic building block 10 may be included in a monolithic building structure, typically such that first portion 20 (or cross-sectional line 1C) is disposed closer to the interior of the structure and second portion 22 (or cross-sectional line ID) is disposed closer to the exterior of the structure.

In some embodiments, the monolithic building structure comprises a plurality of monolithic building blocks similar to block 10 of Figures lA to ID, the plurality including at least a first and a second monolithic building block, the first and second monolithic building blocks being rigidly attached to one another. In some embodiments, the plurality of monolithic building blocks form at least a portion of a wall of a building. In some embodiments, the plurality of monolithic building blocks form at least a portion of a ceiling.

Reference is now made to Figure 2, which is a flow chart illustration of a method for fabrication of a monolithic building block 10 as shown in Figures lA to ID, according to an aspect of the present invention.

As seen in Figure 2, at step 200, the first aggregate material 16, optional second aggregate material 18, and cementitious material 14, and an aqueous liquid, such as water, are mixed to form a substantially uniform slurry.

In some embodiments, a weight ratio of the first aggregate material to said second aggregate material is within a range of 3:1 to 300:1.0, 5:1 to 200:1, or 5:1 to 150:1.

In some embodiments, the slurry is created and mixed using a mixer, and is then transferred to a vessel suitable for carrying out the following method steps as described hereinbelow. In other embodiments, the slurry is created and mixed directly in the vessel suitable for carrying out the following method steps.

In some embodiments, the dimensions of the vessel are suited to the dimensions of a single resulting block 10, with little waste.

As seen at step 202, the slurry in the vessel is vibrated to effect at least partial stratification of the first and second aggregate materials within the slurry. Vibration may be carried out using any suitable device, such as a vibrating table. The intensity and duration of vibration required for stratification of the first and second aggregate materials is dependent on the specific composition of the slurry and the volume and weight of the vibrated materials. In some embodiments, a suitable intensity of vibration is achieved in the range of 1,000-10,OOOrpm {i.e., the RPM of the vibration table motor), more typically in the range of 2,500-4,500rpm. In some embodiments, the slurry is vibrated for a duration of 15 seconds to 5 minutes, more typically, 30 seconds to 5 minutes or 45 seconds to 5 minutes.

Should the vibration intensity be too low, there may be insufficient shear forces, and the segregation may be impaired. In addition, the relatively light aggregate (with respect to the cementitious medium) material may be trapped within the heavy aggregate material. Should the vibration intensity be too high, however, segregation may also be impaired, as the relatively heavy aggregate material may settle poorly, while the relatively light aggregate material may be more evenly distributed over the height of the block.

At step 204, following at least partial stratification of the aggregate materials within the slurry, the slurry is allowed to set within the vessel for a suitable duration, for example, 24 hours.

Once the slurry has set within the vessel, the resulting block is removed from the vessel, at step 206, and cured (e.g., for an additional 14 days), typically under room conditions.

EXAMPLES

Reference is now made to the following Examples, which together with the above description, illustrate the invention in a non-limiting fashion.

The main ingredients used in effecting these Examples are identified hereinbelow: binder - cement: OPC CEM-I 52.5R, Nesher Industries (Israel); gravel - 4.75-9.5 mm, Dragot quarry, Negev Industrial Minerals (Israel); sand - silica sand 30-40 - Negev Industrial Minerals (Israel); expandable polystyrene - Versalis S.P.A.; cement retardant - sodium tripolyphosphate; cellulose ether - Xylose MH6000 YP4; polymer binder powder - DA 1400; cellulose fibers - Arbocell 500 ZZC; air entrainment agent - Hostapur OSB; superplasticizer - Melment FI Ox

Various instruments used in conjunction with the Examples are identified hereinbelow:

Mixing of the slurry was performed using a Hobart Legacy 5 liter mixer (Hobart Corporation, Troy, Ohio).

Vibration of the slurry was performed using a CONTROLS vibration table 55-C0159L (Controls s.r.l., Cemusco sul Naviglio, Italy).

Cutting of the block was performed using a diamond saw (SHATAL TS 351). EXAMPLE 1

Cement binder (typically lOOOg), heavy aggregate, light aggregate, water, and additives were introduced into a mixing vessel. Various additives, e.g., for improving or controlling process parameters including workability and rheology, were also added, according to the proportions provided in Table 3. The contents of the vessel were then mixed for approximately 1 minute to form a substantially uniform slurry.

Subsequently, the slurry was poured into a substantially cylindrical mold having a diameter of 10cm and a height of 20cm. The mold was transferred to a vibration table and was vibrated at 40% of the maximal intensity of the vibration table, typically for 15-180 seconds.

The vibrated slurry was allowed to set for 24 hours, and was then removed from the mold, cured for an additional 14 days under room conditions, and cut with a diamond saw for observation of the stratification of the aggregates in the resulting block. The resulting block was clearly divided into a first portion and a second portion. Generally, the first portion included mostly heavy aggregate, but also some light aggregate (polystyrene), while the second portion included mostly light aggregate, but also a small amount of heavy aggregate. EXAMPLES 2-15

The procedure used in Example 1 was repeated in Examples 2-15, using heavy aggregate materials of various sizes, and combinations thereof, along with light aggregate materials of various sizes, and combinations thereof. The vibration time was also varied, as shown in Table 2. The additives added, as a weight percentage of the cement binder, are provided in Table 3.

Calculation of density was performed as follows: a tape measure or ruler was used to measure the dimensions of the slices. The weight of each slice, divided by the respective resultant volume, equals the density (or in unitless form - the specific gravity).

Table 1

Specific heat (Thermal mass) and thermal conductivity (resistivity) were measured using the Hot Disc method performed using a THERMAL CONSTANT ANALYZER TPS 2500 S.

Table 2

Table 3

The blocks obtained were characterized by a clear segregation pattern along the length of the block: the first portion or slice contained mostly gravel, with minute amounts of polystyrene, while the second portion or slice contained mostly polystyrene, with small amounts of gravel. Figure 3 is a cross-sectional view of one such monolithic building block 300. Block 300 includes a cementitious matrix 314, having embedded therein a first phase, which includes a first heavy aggregate material (coarse gravel) 316 and a second fine aggregate material (sand) that is difficult to view without magnification.

Also embedded within cementitious matrix 314 is a second phase, which includes a light aggregate material 318, in this case, polystyrene spheres. EXAMPLE 18

The procedure used in Example 1 was repeated in Example 18, using the formulation of Example 2. After curing, the cured block was heated in a furnace at 140°C for 48 hours.

Figure 4 is a cross-sectional view of the monolithic building block 400 obtained. The polystyrene was substantially consumed, leaving (in this case, generally spherical) voids 419 as the light phase, in place, or largely in place of, the polystyrene particles.

The expandable polystyrene for use in conjunction with the present invention may be of a widely varying average diameter, e.g., at least 0.5mm, at least 0.75mm, at least 1mm, at least 2mm, at least 4mm, or at least 6mm, typically at most 18mm, at most 15mm, at most 12mm, or at most 8mm, and more typically, 0.50-15mm, 0.75-12mm, l-12mm, or 1-lOmm. Thus, the void volumes formed may be characterized by these average diameters.

As in the other blocks described hereinabove, block 400 includes a cementitious matrix 414, having embedded therein a first phase, which includes a first, heavy aggregate material 416, in this case, coarse gravel.

As used herein in the specification and in the claims section that follows, the term “percenf’, or “%”, refers to percent by weight, unless specifically indicated otherwise.

As used herein in the specification and in the claims section that follows. the term "contour volume", with regard to a block, or portion of the block, refers to the smallest volume encompassed by the block, or by the portion of the block. By way of example: a cubic block weighing 1.67kg has a length of 20cm, and a single 2cm x 2cm hole passing completely through one dimension of the cube, parallel to the cube face. The contour volume of the block would be 20cm x 20cm X 20cm, less the hole: 2cm x 2cm x 20cm, or 0.72 liters. The average density is 1.67/0.72 = 2.32 kg/liter.

As used herein in the specification and in the claims section that follows, the term "average density", with regard to a block, or portion of the block (e.g., a a cross-sectional slice), is evaluated by dividing the weight of the block or portion thereof, in kg, by the respective contour volume, in liters, of the block or portion thereof

As used herein in the specification and in the claims section that follows, the term "monolithic building block", refers to a building block devoid of an adhesive layer connecting between sections of the monolithic block, or, in the case of a building block having such an adhesive layer connecting between sections of the building block, the term "monolithic building block", refers to a continuous portion of that block, that is devoid of an adhesive layer.

It will be appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination. Similarly, the content of a claim depending from one or more particular claims may generally depend from the other, unspecified claims, or be combined with the content thereof, absent any specific, manifest incompatibility therebetween.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A monolithic building block, comprising: (a) a cementitious matrix; (b) a first phase; and (c) a second phase; said first phase including at least a first aggregate material, said aggregate material and said second phase disposed within said cementitious matrix to form the monolithic building block; wherein a first cross-sectional slice of the block, taken in a first direction, has a first average density, pi; wherein a second cross-sectional slice of the block, taken in said first direction, has a second average density, pi; the monolithic building block having at least one of the following structural properties: (1) a differential density (pi - pi) between said first and second cross-sectional slices is at least 300 kg/m^; (2) a thermal conductivity of said second cross-sectional slice is at most 0.36 W/(m*K); and (3) a thermal mass ratio of said first and second cross-sectional slices, per unit volume, is at least 2:1.

2. The monolithic building block of claim 1, said second cross-sectional slice having a compressive strength, along said first direction, of at least 0.5 MPa, at least 0.75MPa, at least 1 MPa, at least l.SMPa, at least 2.5MPa, or at least 4MPa, and at most 15MPa, at most 12 MPa, at most 10 MPa, at most 8 MPa, or at most 6 MPa.

3. The monolithic building block of claim 1 or claim 2, a compressive strength ratio of said first and second cross-sectional slices, measured along said first direction, being at least 3:1, at least 5:1, at least 10:1, at least 20:1, at least 50:1, or at least 100:1, and optionally, at most 1000:1, at most 700:1, at most 500:1, at most 300:1, at most 200:1, almost 150:1, or at most 120:1.

4. The monolithic building block of any one of claims 1 to 3, said thermal conductivity of said second cross-sectional slice being at most 0.32 W/(m*K), at most 0.28 W/(m*K), at most 0.25 W/(m*K), at most 0.22 W/(m*K), at most 0.20 W/(m*K), at most 0.18 W/(m*K), or at most 0.15 W/(m*K).

5. The monolithic building block of any one of claims 1 to 4, the thermal conductivity, or a thermal conductivity, of said second cross-sectional slice being at least 0.03 W/(m*K), at least 0.07 W/(m»K), at least 0.10 W/(m*K), at least 0.12 W/(m*K), or at least 0.14 W/(m*K).

6. The monolithic building block of any one of claims 1 to 5, a thermal conductivity ratio between said first and said second cross-sectional slices being within a range of 0.03 to 0.25.

7. The monolithic building block of any one of claims 1 to 6, said differential density between said first and second cross-sectional slices being at least 325 kg/m^ at least 350 kg/m^, at least 400 kg/m^ at least 500 kg/m^, at least 600 kg/m^, at least 800 kg/m^, at least 1000 kg/m^, at least 1200 kg/m^, at least 1400 kg/m^, at least 1600 kg/m^, at least 1800 kg/m^, or at least 2000 kg/m^.

8. The monolithic building block of any one of claims 1 to 7, a differential density between said first and second cross-sectional slices being at most 3000 kg/m^, at most 2700 kg/m^, at most 2400 kg/m^, or at most 2200 kg/m^.

9. The monolithic building block of any one of claims 1 to 8, said second phase including a second aggregate material, said second aggregate material optionally including, or mainly including, particles selected from the group consisting of polystyrene, hemp, cork, expanded glass, light expanded clay aggregate (LECA), pumice, pearlite, scoria, and vermiculite.

10. The monolithic building block of any one of claims 1 to 9, said first aggregate material including, or mainly including, particles selected from the group consisting of sand and crushed stone.

11. The monolithic building block of any one of claims 1 to 10, a weight ratio of said first aggregate material to said second aggregate material being within a range of 5:1 to 1000:1, 10:1 to 500:1, or 20:1 to 500:1.

12. The monolithic building block of any one of claims 1 to 11, said thermal mass ratio being at least 2:1, at least 4:1, or at least 10:1.

13. The monolithic building block of any one of claims 1 to 12, said thermal mass ratio being at most 16:1, at most 14:1, or at most 12:1.

14. The monolithic building block of any one of claims 1 to 11, said thermal mass ratio being within a range of 2:1 to 16:1, 3:1 to 15:1, or 5:1 to 15:1.

15. The monolithic building block of any one of claims 1 to 14, a void fraction within the block being at most 0.65, at most 0.55, at most 0.50, or at most 0.4.

16. A monolithic building structure comprising a plurality of monolithic building blocks according to any one of claims 1 to 15, said plurality including at least a first monolithic building block, and a second monolithic building block rigidly attached thereto.

17. The monolithic building block of claim 16, said plurality of monolithic building blocks forming at least a portion of a wall of a building.

18. The monolithic building block of claim 16, said plurality of monolithic building blocks forming at least a portion of a ceiling.

19. A method of producing a monolithic building block, the method comprising the steps of: (a) introducing a first aggregate material, a light phase, with respect to said first aggregate material, a cementitious material, and an aqueous liquid, to a vessel, to form a slurry; (b) vibrating said slurry to effect at least a partial stratification of said first aggregate material and said light phase, within said slurry; (c) setting slurry within a mold, to form a set block; and (d) removing said set block from said mold.

20. The method of claim 19, said light phase including a second aggregate material.