IL311005A - Light weight insulating construction block system - Google Patents

Description

LIGHT WEIGHT INSULATING CONSTRUCTION BLOCK SYSTEM FIELD AND BACKGROUND OF THE INVENTION The present invention, in some embodiments thereof, relates to a light weight insulating block system and, more particularly, but not exclusively, with at least one pre-finish face.

US Patent no. US10053876 appears to disclose, "Embodiments of modular building units (blocks) ... that can be stacked to provide insulating concrete forms (ICFs). The blocks are formed of a foamed polymer material, such as foamed polyurethane. The blocks, when assembled together in an ICF, are configured to form one or more vertical columns of concrete and one or more horizontal beams of concrete intersecting the one or more columns, in a manner of post and beam construction. The blocks can be tightly interlocked with other blocks in a construction process. The disclosed blocks can include significant interior space for rebar and concrete to be inserted to construct the structure. Molds and methods for producing modular units are also disclosed. The molds and methods enable rapid production and removal of modular building units from the molds. Methods of constructing structures using the modular building units are also disclosed." Canadian patent no. CA1081911 appears to disclose, "A wall construction ... that uses light weight foam plastic blocks with an outer skin of fiberglass or concrete. The blocks are stacked between top and bottom rails with a sealing element in between them. Cable means extend between the rails to securely tie the blocks and rails on a foundation." Chinese utility model no. CN219690863U appears to disclose, "a structural self-heat-preservation and decoration integrated building block which comprises a heat preservation core material and a building block body, the heat preservation core material is wrapped by a reinforcing grid, the building block body is provided with a containing cavity in the vertical direction, the containing cavity penetrates through the building block body, and the building block body wraps the heat preservation core material to form an outer enclosure structure. The heat preservation core material is provided with a bearing structure in the vertical direction, and the heat preservation core material is further provided with a connecting structure in the vertical direction. The self-insulation and decoration integrated building block disclosed by the utility model integrates a building insulation function, a wall enclosure function and a decoration function, and the wall can meet the energy-saving standard requirements of the existing building without additionally taking insulation measures, so that an integrated structure of insulation, energy conservation and wall enclosure is realized; and a building energy-saving and structure decoration integrated technology with the same service life is realized." International patent application no. WO2021028901 appears to disclose, "A wall panel has decorative board on opposite sides and a frame inset around the edges. Low density concrete fills the frame in between the boards. As a result, a wall can be built up by putting rails and/or studs and then sliding panels onto the rails and/or studs. The boards overlap the rails and/or studs. The panel is the entire height of a standard room with an unfilled top section that can be cut to size to fit lower ceilings." US Patent no. US4694624 appears to disclose, "A modular, pre-insulated and pre-finished structural building block comprised of structural and insulating elements, fastening rods for the attachment of building blocks to one another and to other wall components, and facing elements of selected materials and finishes affixed to the building block. The building block incorporates into its construction common and varying sizes, shapes, and configurations that fasten to one another and to other wall components in the assembly of a wall, and may be unfastened from each other in the disassembly of a wall without damage to the building blocks or wall components. The building block further incorporates into its construction fastening components that attach to fastening couplings in anchor plates, top plates, door and window frames, window sills, and headers. Additionally, the building block incorporates into its construction electrical boxes and wiring conduits attached to and within selected building blocks." Chinese patent application no. CN105089166 appears to disclose, "a self-supporting assembled light-weight heat insulation wall body, and relates to a self-supporting light-weight heat insulation wall body of a building. The self-supporting assembled light-weight heat insulation wall body solves the problems of prefabricated installation inconvenience, poor energy-saving and heat-insulation performance, great steel consumption, high manufacturing cost and the like of a wall body in the prior art and structurally comprises prefabricated wall boards and foundation beams, wherein the heat insulation layer of each prefabricated wall body consists of two kinds of heat insulation materials or various kinds of heat insulation materials; an inside heat insulation layer is made of light-weight inorganic heat insulation materials which meet a certain fire-resistant limit and have certain strength; an outside heat insulation layer is made of non-load-bearing heat insulation materials; the protection layer is a prefabricated board protection layer; or the heat insulation layer of each prefabricated wall board is made of inorganic heat insulation materials; the protection layer is a prefabricated board production layer; various materials of the prefabricated wall boards are connected into a whole; the prefabricated wall boards and the foundation beams are fixed; the prefabricated wall boards are mutually connected; and the self-supporting assembled light-weight heat insulation wall body is formed. The self-supporting assembled light-weight heat insulation wall body has the advantages that the energy-saving and heat-insulation effects are good; the ultra-low energy consumption standard can be easily reached; the prefabrication and the installation are convenient; the manufacturing cost is low; the safety is high; and the application range is wide." Other art includes US patent application publication no. US20080115455A1, US patent no. 7790302, US Patent no. 4694624, Chinese patent application publication no. CN1215781A, Chinese utility application no. CN210032430U, Chinese utility application no. CN203613708U, Chinese patent application publication no. CN101260718A, International patent application publication no. WO2016205858A1, Canadian patent no. CA1142773A and International patent application no. WO2009002221.

SUMMARY OF THE INVENTION According to an aspect of some embodiments of the invention, there is provided a pre-finished block including: a skeleton composed of a first material, wherein the skeleton defines at least one hollow and the first material is low density; and a finish on at least one face of the block. According to some embodiments of the invention, the first material is heat resistant, fire resistant, fireproof, water resistant, or a combination thereof. According to some embodiments of the invention, the first material includes Styrofoam. According to some embodiments of the invention, the first material is thermally insulating material. According to some embodiments of the invention, the first material is selected from the group including: a hardened foam, polyurethane foam, phenolic foam, Polyisocyanurate spray foam, Closed-cell polyurethane spray foam, Phenolic spray foam, Urea-formaldehyde panels, Drywall, Urea foam, Extruded expanded polystyrene (XPS) high-density, Polystyrene board, Phenolic rigid panel, Urea-formaldehyde foam, High-density fiberglass batts, Extruded expanded polystyrene (XPS) low-density, Icynene loose-fill (pour-fill), Molded expanded polystyrene (EPS) high-density, Rice hulls, Fiberglass batts, Molded expanded polystyrene (EPS) low-density, Icynene spray, Open-cell polyurethane spray foam, Cardboard, Rock and slag wool batts, Cellulose loose-fill, Cellulose wet-spray, Rock and slag wool loose-fill, Fiberglass loose-fill, Polyethylene foam, Cementitious foam, Perlite loose-fill, Wood panels, such as sheathing, Fiberglass rigid panel, Vermiculite loose-fill, Vermiculite, Papercrete, Softwood, Wood chips and other loose-fill wood products, Aerated/cellular concrete (5% moisture), Styrofoam, fiberglass, gypsum, laminate, melamine, resin, Type X drywall, Type C drywall, wood, hardened plastic, or any combination thereof. According to some embodiments of the invention, the at least one hollow pierces through the block. According to some embodiments of the invention, the at least one hollow pierces the block perpendicularly to the finished face. According to some embodiments of the invention, the at least one hollow is filled with a second material. According to some embodiments of the invention, the second material is configured to provide an internal support structure. According to some embodiments of the invention, the finish is decorative and/or protective. According to some embodiments of the invention, the finish is heat resistant, fire resistant, fireproof, water resistant, dirt resistant, or any combination thereof. According to some embodiments of the invention, the finish includes ceramic tiles, paint, fiberglass, gypsum, laminate, melamine, resin, Type X drywall, Type C drywall, wood, aluminum, stainless steel, hardened plastic, cast iron, zinc alloy, tin, chrome, or any combination thereof. According to an aspect of some embodiments of the invention, there is provided a structure including a plurality of pre-finished, wherein each block includes: a skeleton composed of a low density first material, wherein the skeleton includes at least one hollow; and a finish on at least one face of the block; and a support structure. According to some embodiments of the invention, the first material is heat resistant, fire resistant, fireproof, water resistant, or a combination thereof. According to some embodiments of the invention, the first material is a light weight thermally insulating material. According to some embodiments of the invention, the first material is selected from the group including: a hardened foam, polyurethane foam, phenolic foam, Polyisocyanurate spray foam, Closed-cell polyurethane spray foam, Phenolic spray foam, Urea-formaldehyde panels, Drywall, Urea foam, Extruded expanded polystyrene (XPS) high-density, Polystyrene board, Phenolic rigid panel, Urea-formaldehyde foam, High-density fiberglass batts, Extruded expanded polystyrene (XPS) low-density, Icynene loose-fill (pour-fill), Molded expanded polystyrene (EPS) high-density, Rice hulls, Fiberglass batts, Molded expanded polystyrene (EPS) low-density, Icynene spray, Open-cell polyurethane spray foam, Cardboard, Rock and slag wool batts, Cellulose loose-fill, Cellulose wet-spray, Rock and slag wool loose-fill, Fiberglass loose-fill, Polyethylene foam, Cementitious foam, Perlite loose-fill, Wood panels, such as sheathing, Fiberglass rigid panel, Vermiculite loose-fill, Vermiculite, Papercrete, Softwood, Wood chips and other loose-fill wood products, Aerated/cellular concrete (5% moisture), Styrofoam, fiberglass, gypsum, laminate, melamine, resin, Type X drywall, Type C drywall, wood, hardened plastic, or any combination thereof. According to some embodiments of the invention, the at least one hollow pierces through the pre-finished block. According to some embodiments of the invention, the at least one hollow pierces the pre-finished block perpendicularly to the finished face. According to some embodiments of the invention, the hollows of vertically and/or horizontally adjacent pre-finished blocks overlap at least in part. According to some embodiments of the invention, the support structure is an internal support structure, an external support structure, or both. According to some embodiments of the invention, the internal support is located within the hollows of the plurality of pre-finished blocks. According to some embodiments of the invention, the internal support structure includes a second material. According to some embodiments of the invention, the second material is a filler. According to some embodiments of the invention, the internal support structure is a metal frame. According to some embodiments of the invention, the external support structure is a metal frame. According to some embodiments of the invention, the external support structure includes a retainer. According to some embodiments of the invention, the external support structure is located between and/or connected to vertically and/or horizontally adjacent blocks. According to some embodiments of the invention, the external support structure is selected from mortar, glue, frame, or any combination thereof.

According to an aspect of some embodiments of the invention, there is provided a method of constructing a structure from pre-finished blocks, the method including: placing the pre-finished blocks in a required position; inserting at least one retainer; adding an internal support structure; adding an external support structure; and building further vertical and/or horizontal layers extending therefrom. According to some embodiments of the invention, the pre-finished blocks are positioned such that at least one internal hollow of vertically and/or horizontally adjacent pre-finished blocks overlap at least in part. According to some embodiments of the invention, the internal support structure is poured into the at least partially overlapping hollows. According to some embodiments of the invention, the method the positioning include stacking one of the pre-finished blocks onto another of the prefinished blocks.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.

Figs. 1A-D: Schematic illustrations of exemplary pre-finished blocks, in accordance with an embodiment of the current invention.

Figs. 2A and 2B: Schematic illustrations of exemplary pre-finished blocks and a retainer, in accordance with embodiments of the current invention.

Fig. 3: A schematic illustration of exemplary pre-finished blocks with a finish on one surface, in accordance with an embodiment of the current invention.

Figs. 4A and 4B: Schematic illustrations of use of the pre-finished blocks in the construction of a structure, in accordance with embodiments of the current invention.

Fig. 5: A block diagram describing a pre-finished block, in accordance with an embodiment of the current invention.

Fig. 6: A block diagram describing a pre-finished block, in accordance with an embodiment of the current invention.

Fig. 7: A block diagram describing wall constructed of prefinished blocks, in accordance with an embodiment of the current invention.

Fig. 8: A flow chart describing a method of producing a pre-finished block, in accordance with an embodiment of the current invention.

Fig. 9: A flow chart describing a method of building a wall with pre-finished blocks, in accordance with an embodiment of the current invention.

DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION The present invention, in some embodiments thereof, relates to a light weight insulating block system and, more particularly, but not exclusively, with at least one finished face.

OVERVIEW The present invention, in some embodiments thereof, relates to a light weight insulating block. Optionally, each insulating block may have at least one finished face. Optionally, the finished face may be decorative, and/or protective, and/or heat resistant, and/or fire resistant, and/or fireproof, and/or water resistant, and/or dirt resistant.

Advantageously, according to some embodiments, the blocks of the system may be easy to stack, e.g., for transportation, construction of internal and/or external walls, etc. Additionally, or alternatively, the block may be constructed from a highly thermally insulating material, Optionally, a structure constructed from such block may be highly insulating. For example, the block may include a skeleton of a material of thermal conductivity less than 0.W/mK and/or between 0.01 to 0.03 W/mK and/or between 0.03 to 0.05 W/mK and/or make between 0.05 to 0.1 W/mK. In some embodiments, a construction system is supplied which can support the weight of a building while providing good insulation and preventing water penetration. Optionally, the skeleton of the block may support other blocks but not weight of the building for example, the crush resistance of the skeleton may range between 0.05 to 0.MPa and/or be less than 0.05 MPa and/or range between 0.3 to 5 MPa and/or range between to 20 MPa and/or range between 20 to 50 MPa.

According to some embodiments, the thermally insulating material may have an R-value (measure of insulation) ranging between about 0.15 to about 10, and/or between about 0.5 to about 5, and/or between about 1 to about 3.

Non-limiting examples of suitable thermally insulating materials include a hardened foam, polyurethane foam, phenolic foam, Polyisocyanurate spray foam, Closed-cell polyurethane spray foam, Phenolic spray foam, Urea-formaldehyde panels, Drywall, Urea foam, Extruded expanded polystyrene (XPS) high-density, Polystyrene board, Phenolic rigid panel, Urea-formaldehyde foam, High-density fiberglass batts, Extruded expanded polystyrene (XPS) low-density, Icynene loose-fill (pour-fill), Molded expanded polystyrene (EPS) high-density, Rice hulls, Fiberglass batts, Molded expanded polystyrene (EPS) low-density, Icynene spray, Open-cell polyurethane spray foam, Cardboard, Rock and slag wool batts, Cellulose loose-fill, Cellulose wet-spray, Rock and slag wool loose-fill, Fiberglass loose-fill, Polyethylene foam, Cementitious foam, Perlite loose-fill, Wood panels, such as sheathing, Fiberglass rigid panel, Vermiculite loose-fill, Vermiculite, Papercrete, Softwood, Wood chips and other loose-fill wood products, Aerated/cellular concrete (5% moisture), Styrofoam, fiberglass, gypsum, laminate, melamine, resin, Type X drywall, Type C drywall, wood, hardened plastic, etc. For example, the density of the skeleton may be less than 10 kg/m and/or range between 10 to 100 k/m and/or range between 100 to 200 k/m and/or range between 2to 500 k/m According to some embodiments, the block may be constructed with a block skeleton containing a thermally insulating material. Optionally, the block may be light weight. Optionally, the block may be solid. Optionally, the block may be hollow. Optionally, the block may include one or more hollows. Optionally, the hollows may pierce completely through the block (e.g., from top to bottom such that two opposite faces may be open). Optionally, the one or more hollows pierce the block perpendicularly to the finished face/s. Optionally, there may be no path crossing the block perpendicular to the finished face of the block that does not pass through the high insulating skeleton and/or at least 90% of the area of the block perpendicular to the finished face may be insulated by the insulating skeleton. Optionally, a structure (e.g., a wall) made of blocks of an embodiment of the current invention may include spaces cross the wall that bypass the low thermal conductivity skeleton of the blocks over less than 1% of its area and/or between 1 to 5% of its area and/or between 5 to 10% of its area and/or between to 25 of its area.

According to some embodiments, the blocks may include one or more enclosed hollows. Optionally, the hollows may have various shapes, e.g., cylinder, sphere, prism, cone, cube, cuboid, etc. Optionally, the hollows may be symmetrical and/or asymmetrical. Optionally, the hollows may be symmetrically and/or asymmetrically distributed within the block. Optionally, the block may include a second material within a central hollow, e.g., a filler, pipes, electric cables, etc. Optionally, the blocks may be core filled blocks. Optionally, the block may be constructed of a material which may be heat resistant and/or fire resistant and/or fireproof and/or water resistant.

According to some embodiments, the block may include a finish, such as a protective layer, decorative layer, waterproof layer, weather resistant layer, fireproof layer, fire resistant layer, insulating layer, dirt resistant, etc. Optionally, the finish may include ceramic tiles, paint, fiberglass, gypsum, laminate, melamine, resin, Type X drywall, Type C drywall, wood, aluminum, stainless steel, hardened plastic, cast iron, zinc alloy, tin, chrome, etc. Optionally, the block may include one finish on an outside face and a different finish on an inside face, e.g., gypsum on the inside face, aluminum etc. on the outside face. Optionally, the block may include the same finish on the outside face and the inside face. Optionally, only one face of the block may include a finish. Optionally, the block may not include a finish.

According to some embodiments, the block may be pre-finished on one or more faces, e.g., on an exterior face, interior face, upper face, lower face, or any combination thereof. Optionally, the block may be pre-finished off site. Optionally, the block may be partially pre-finished off site, e.g., one face may be pre-finished off site and one or more additional faces may be finished on site and/or in situ. Optionally, one or more faces of the block may be finished on site. Optionally, the block may be finished on site. Optionally, one or more blocks may be used in the construction of a structure, e.g., wall, etc. Optionally, the blocks may include a finish prior to use in construction.

According to some embodiments, the block may be pre-formed off site. Optionally, the block may be pre-formed without finishing off-site. Optionally, the block may be used in the construction of a building. Optionally, the block may be finished on site.

According to some embodiments, the block may be covered by a protective coating. Optionally, the protective coating may be heat resistant, fire resistant, fireproof and/or water resistant. Optionally, the block may be covered and/or coated and/or bonded and/or glued and/or heat soldered to a protective coating, such as a veneer. Optionally, the protective coating may cover all or part of a block, e.g., an inner surface, an outer surface, an exposed surface, etc.

According to some embodiments, the block may include a decorative layer. Optionally, the decorative layer may be a coating. Optionally, the decorative layer may be printed. Optionally, the decorative layer may be ceramic, e.g., ceramic tiles, etc. Optionally, the decorative layer may be drywall. Optionally, the decorative layer may be printed directly onto a material which may be applied to a block.

According to some embodiments, the finish may be removable and/or permanent. Optionally, the finish may be continuous with the block and a preexisting structure. Optionally, the finish may be attached to the block, e.g., by glue, screws, clicked, slid, mortared, and/or locked in place by an interference element, or a combination thereof. Alternatively, or additionally, the old finish may be removed, and replaced by a new finish, e.g., with a different design, etc.

According to some embodiments, the block may include one or more hollows. Optionally, the blocks may serve as a mold. Optionally, a second material may be poured into the hollows, e.g., concrete, etc. Optionally, the second material may be a heavier material than the material from which the block is constructed. Optionally, the second material may stabilize the block. Optionally, the second material may be configured to be weight bearing.

According to some embodiments, one or more layers of the block may be laid down for use in construction of a structure, e.g., similar to cinder blocks, concrete blocks, integrated concrete foam construction, etc. Optionally, the hollows of vertically and/or horizontally adjacent pre-finished blocks may partially and/or completely overlap. Optionally, a second material may be poured into the hollows, Optionally, the second material may form a continuous material throughout the layers and/or structure. Optionally, the second material may solidify within the hollows of the pre-finished blocks. Optionally, once solid, the second material may provide internal support to the structure. Optionally, the second material may be reinforced by one or more metal bars and/or frames.

According to some embodiments, the one or more layers of blocks may include a retainer. Optionally, the retainer may be a plastic spacer. Optionally, the retainer may be a metal pins with protrusions on the ends. Optionally, the protrusions may prevent the block from moving and/or bulging, e.g., due to their weight and/or weight of a filling material. Optionally, the retainers may be placed at the corners between the blocks. Optionally, the retainers may be placed between blocks. Optionally, the retainers may be removable. Optionally, the retainers may be permanent.

According to some embodiments, the one or more layers of blocks may include a support structure. Optionally, the support structure may be internal and/or external to the block. Optionally, the support structure may include mortar between successive blocks and/or adjacent blocks. Optionally, the support structure may include a retainer.

According to some embodiments, the support structure may be a frame. Optionally, the frame may be internal to the blocks, e.g., rebar, metal frame, metal skeleton, etc. Optionally, the frame may be external to the blocks. Optionally, the frame may be composed of metal and/or plastic and/or ceramic. Optionally, the frame may include bars, rods, runner, etc.

According to some embodiments, the support structure may be a filling within a hollow of a block. Optionally, the support structure may be poured into continuous hollows in and/or in between the blocks. Optionally, the filler may be concrete, foamcrete, a hardened foam, a mixture of concrete and an elastomer, a mixture of concrete and one or more types of light weight particles, etc.

According to some embodiments, the blocks may not include continuous hollows from the inside face to the outside face. Optionally, the blocks may not include filled continuous hollows from the inside face to the outside face. Optionally, the lack of continuous hollows from the inside face to the outside face may aid in preserving the thermal insulating properties of the blocks and/or structure constructed therefrom.

According to some embodiments, the blocks may have a profile which may be square, rectangular, hexagonal, polygonal, triangular, etc. Optionally, the blocks for use in construction may have the same profile. Optionally, the blocks for use in construction may have different profiles. Optionally, the blocks may have at least one profile which may be flat and/or curved.

According to some embodiments, the blocks may be prefabricated to a particular size. Optionally, the blocks may be cut to a required size. Optionally, the blocks may be prefabricated and then cut to the required size on-site. Optionally, the blocks may have at least one profile with a length ranging between about 10 cm to about 2 m, and/or between about 15 cm to about m, and/or between about 20 cm to about 50 cm, and/or between about 15 cm to about 40 cm. Optionally, the size of the block may depend on the use of the block, e.g., load bearing blocks may be larger than non-load bearing blocks, or vice versa.

According to some embodiments, the walls of the blocks may have a thickness ranging between about 0.5 cm to about 15 cm, and/or between about 1 cm to about 10 m, and/or between about 2 cm to about 5 cm, and/or between about 1 cm to about 3 cm. Optionally, the thickness of the walls of a block may depend on the degree of thermal insulation required, e.g., in very hot and/or very cold environments greater thermal insulation may be required than in more temperate environments.

SPECIFIC EMBODIMENTS Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and/or methods set forth in the following description and/or illustrated in the drawings and/or the Examples. The invention is capable of other embodiments or of being practiced or carried out in various ways.

Reference is now made to the figures.

Figs. 1A-D are schematic illustrations of exemplary pre-finished blocks, in accordance with an embodiment of the current invention. For example, the pre-finished block may be constructed with a block skeleton 102 containing a thermally insulating material. Optionally, the block may be light weight. Optionally, the block may be solid (e.g., Fig. 1D). Optionally, the block may be hollow. Optionally, the block may include one or more hollows 104 (e.g., Figs. 1A, 1B, and 1C). Optionally, the hollows may pierce completely through the block (e.g., from top to bottom such that two opposite faces may be open. Optionally, the blocks may include one or more enclosed hollows. Optionally, the hollows may have various shapes, e.g., cylinder, sphere, prism, cone, cube, cuboid, etc. Optionally, the hollows may be symmetrical and/or asymmetrical. Optionally, the hollows may be symmetrically and/or asymmetrically distributed within the block. Optionally, the block may include a second material within a central hollow, e.g., a filler, pipes, electric cables, etc. Optionally, the blocks may be core filled blocks. Optionally, the block may be constructed of a material which may be heat resistant and/or fire resistant and/or fireproof and/or water resistant. Optionally, hollows of adjacent blocks may be connected and/or continuous. Optionally, hollows of blocks stacked one on top of the other may be connected and/or continuous.

For example, the blocks may be constructed from a light weight thermally insulating material, e.g., polystyrene, Styrofoam, etc. Optionally, the blocks may be hollow. Optionally, the blocks may be filled with a second material, e.g., concrete.

Figs. 2A and 2B are a schematic illustrations of exemplary pre-finished blocks and a retainer, in accordance with an embodiment of the current invention. For example, each block may include a block skeleton 204, e.g., comprising a thermally insulating material, optionally with one or more hollows 202. The blocks may be stacked and/or placed adjacent to each other to form a structure, e.g., a wall. For example, during building the blocks may be stacked one the other and/or one supporting the other.

The one or more layers of blocks may include one or more retainers 206 placed between vertically and/or horizontally adjacent blocks. Optionally, the retainer may include a plastic spacer. Optionally, the retainer may include a metal pin. Optionally, the retainer may include protrusions 207 on one or more ends. Optionally, the protrusions may prevent the block from moving and/or bulging, e.g., due to the weight of the blocks and/or the weight of a filling material. Optionally, the retainers may be placed at the corners between the blocks. Optionally, the retainers may be placed between blocks. Optionally, the retainers may be removable. Optionally, the retainers may be permanent.

Fig. 3 is a schematic illustration of exemplary pre-finished blocks with a finish on one surface, in accordance with an embodiment of the current invention. For example, the block be pre-finished e.g., it may be produced off site with one or more finished faces, Optionally, the block may be pre-finished on one or more faces, e.g., on an exterior face, interior face, upper face, lower face, or any combination thereof. The finish may be a protective layer, decorative layer, waterproof layer, weather resistant layer, fireproof layer, fire resistant layer and/or insulating layer, etc. Optionally, the finish may include ceramic tiles, paint, fiberglass, gypsum, laminate, melamine, resin, Type X drywall, Type C drywall, wood, aluminum, stainless steel, hardened plastic, cast iron, zinc alloy, tin, chrome, etc. Optionally, the block may include one finish on an outside face and a different finish on an inside face, e.g., gypsum on the inside face, aluminum etc. on the outside face. Optionally, the block may include the same finish on the outside face and the inside face. Optionally, only one face of the block may include a finish. Optionally, more than one face of the block may include a finish.

For example, the block may include a block skeleton 304 comprising a thermally insulating material, optionally including one or more hollows 302 and a finish 306, e.g., ceramic tiles. Optionally, the finish may be adhered to a face of the block, e.g., by glue, mortar, welding, attaching with nails, crews, clips, frame, etc.

Figs. 4A and 4B are a schematic illustration of an exemplary use of the pre-finished blocks in the construction of a structure, in accordance with an embodiment of the current invention. For example, the pre-finished blocks may be used in the construction of a structure, e.g., wall, etc. Optionally, the blocks may include a block skeleton 402 comprising a thermally insulating material, optionally including one or more hollows 404 and a finish 406. The one or more layers of blocks may include one or more retainers 408 placed between vertically and/or horizontally adjacent blocks. Optionally, the retainer may include protrusions 407 on one or more ends. The pre-finished blocks may be filled with a second material. Optionally, the second material may be poured into the hollows 404. Optionally, the second material may solidify within the hollows, e.g., concrete, foamcrete, etc.

According to some embodiments, the one or more layers of blocks may include a support structure. Optionally, the support structure may be internal and/or external to the block. Optionally, the support structure may include mortar between successive blocks and/or adjacent blocks. Optionally, the support structure may include a retainer408. Optionally, the retainer may be removable.

According to some embodiments, the support structure may be a frame. Optionally, the frame may be internal to the blocks, e.g., rebar, metal frame, metal skeleton, etc. Optionally, the frame may be external to the blocks. Optionally, the frame may be composed of metal and/or plastic and/or ceramic. Optionally, the frame may include bars, rods, runner, etc.

According to some embodiments, the support structure may be a filling within a hollow of a block. Optionally, the support structure may be poured into continuous hollows in and/or in between the blocks. Optionally, the filler may be concrete, foamcrete, a hardened foam, a mixture of concrete and an elastomer, a mixture of concrete and one or more types of light weight particles, etc.

Fig. 5 is a block diagram describing a pre-finished block, in accordance with an embodiment of the current invention. For example, the pre-finished block 500 may include a block skeleton 502 and a finish 504 on one face. Optionally, the finish may be a protective layer, decorative layer, waterproof layer, weather resistant layer, fireproof layer, fire resistant layer, insulating layer, etc. Optionally, the finish may include ceramic tiles, paint, fiberglass, gypsum, laminate, melamine, resin, Type X drywall, Type C drywall, wood, aluminum, stainless steel, hardened plastic, cast iron, zinc alloy, tin, chrome, etc.

According to some embodiments, the block may be partially pre-finished off site, e.g., one face may be pre-finished off site and one or more additional faces may be finished on site and/or in situ. Optionally, one or more faces of the block may be finished on site. Optionally, the block may be finished on site.

Fig. 6 is a block diagram describing a pre-finished block, in accordance with an embodiment of the current invention. For example, the pre-finished block 600 may include a block skeleton 604 and a finish 602, 608 on more than one face. Optionally, the finish may be a protective layer, decorative layer, waterproof layer, weather resistant layer, fireproof layer, fire resistant layer, insulating layer, etc. Optionally, the finish may include ceramic tiles, paint, fiberglass, gypsum, laminate, melamine, resin, Type X drywall, Type C drywall, wood, aluminum, stainless steel, hardened plastic, cast iron, zinc alloy, tin, chrome, etc. Optionally, the block may include the same finish on the outside face and the inside face. Optionally, the block may include one finish on an outside face and a different finish on an inside face, e.g., gypsum on the inside face, aluminum etc. on the outside face.

Fig. 7 is a block diagram describing a wall constructed of prefinished blocks, in accordance with an embodiment of the current invention. For example, structure 700 may include repeating units 714 (e.g., layers, stacks, or a combination thereof) of pre-finished blocks. Each block may include a block skeleton 704, 710, one or more hollows 716, 720 and a finish 702, 712 at least one face. The pre-finished blocks may be stacked and/or layered vertically and/or horizontally. Optionally, the hollows of vertically and/or horizontally adjacent pre-finished blocks may overlap partially and/or completely. Optionally, structure 700 may include a support structure. Optionally, the support structure may be an internal support structure 718 and/or external support structure 708. Optionally, the support structure may include mortar between vertically and/or horizontally adjacent pre-finished blocks. Optionally, the support structure may include a retainer 706.

According to some embodiments, the support structure may be a frame. Optionally, the frame may be internal to the blocks, e.g., rebar, metal frame, metal skeleton, etc. passing through one or more hollows of the pre-finished blocks. Optionally, the frame may be external to the blocks, e.g., rebar, metal frame, metal skeleton, etc. connected to one or more outer surfaces of the pre-finished blocks. Optionally, the frame may be composed of metal and/or plastic and/or ceramic. Optionally, the frame may include bars, rods, runner, etc.

According to some embodiments, the support structure may be a filling within a hollow of a block. Optionally, the hollows of vertically and/or horizontally adjacent pre-finished blocks may overlap partially and/or completely. Optionally, a second material may be poured into the interconnected hollows in and/or in between the blocks, e.g., to form a continuous network of the filling material. Optionally, the second material may form a continuous material throughout the layers and/or structure. Optionally, the second material may form a series of columns, pillars, layers, tubes, lattices, etc. within the structure. Optionally, the second material may solidify within the hollows of the pre-finished blocks. Optionally, once solid, the second material may provide internal support to the structure. Optionally, the second material may be reinforced by one or more metal bars and/or frames. Optionally, the second material may be concrete, foamcrete, a hardened foam, a mixture of concrete and an elastomer, a mixture of concrete and one or more types of light weight particles, etc.

Fig. 8 is a flow chart describing a method of producing a pre-finished block, in accordance with an embodiment of the current invention. For example, in method 800, the block skeleton is constructed 802 from a thermally insulating material. The block skeleton may optionally include one or more hollows. One or more faces of the block skeleton are finished 804. Optionally, an internal support structure may be inserted 806 within the block skeleton and/or one or more hollows thereof.

Fig. 9 is a flow chart describing a method of building a wall with pre-finished blocks, in accordance with an embodiment of the current invention. For example, in method 900, each pre-finished block is placed 902 as required to construct a structure. Optionally, retainers may be inserted 904 between vertically and/or horizontally adjacent pre-finished blocks. Optionally, an internal support structure may be added 906 within and/or connecting between the interiors of vertically and/or horizontally adjacent pre-finished blocks. Optionally, an external support structure may be added 908 between and/or along one or more external faces of vertically and/or horizontally adjacent pre-finished blocks. Optionally, further layers may be built 9onto previous layers of the structure.

GENERAL It is expected that during the life of a patent maturing from this application many relevant building technologies, artificial intelligence methodologies, computer user interfaces, image capture devices will be developed and the scope of the terms for design elements, analysis routines, user devices is intended to include all such new technologies a priori.

Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

As used herein the term "about" refers to ± l0% The terms "comprises", "comprising", "includes", "including", "having" and their conjugates mean "including but not limited to".

The term "consisting of" means "including and limited to".

The term "consisting essentially of" means that the composition, method, or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

As used herein, the singular form "a", "an" and "the" include plural references unless the context clearly dictates otherwise.

As used herein, the term "plurality" relates to 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 25, 30, 40, 50, 100, 500, 1,000, etc. or any sub-range therebetween.

The term "R–Value" relates to a rating given to insulation in order to measure its thermal resistance with the standard measurement given in square meter kelvin per watt (m·K/W). It measures the temperature variation over insulation and also the amount of heat transferred through the insulating material.

As used herein, the terms "panel" and "block" may be used interchangeably, and relate to a unit of pre-formed material for use in the system disclosed herein.

As used herein, the term "pre-finished block" may relate to a block manufactured with at least one finished face for use in construction of a structure.

Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, l, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. The phrases "ranging/ranges between" a first indicate number and a second indicate number and "ranging/ranges from" a first indicate number "to" a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may additionally 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 additionally be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

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.

All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation, or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting.

Claims (32)

CLAIMS What is claimed is:

1. A pre-finished block comprising: a skeleton composed of a first material, wherein the skeleton defines at least one hollow and the first material is low density; and a finish on at least one face of the block.

2. The block according to claim 1, wherein the first material is heat resistant, fire resistant, fireproof, water resistant, or a combination thereof.

3. The block according to claim 1, wherein said first material includes Styrofoam.

4. The block according to claim 1, wherein the first material is thermally insulating material.

5. The block according to claim 1, wherein the first material is selected from the group comprising: a hardened foam, polyurethane foam, phenolic foam, Polyisocyanurate spray foam, Closed-cell polyurethane spray foam, Phenolic spray foam, Urea-formaldehyde panels, Drywall, Urea foam, Extruded expanded polystyrene (XPS) high-density, Polystyrene board, Phenolic rigid panel, Urea-formaldehyde foam, High-density fiberglass batts, Extruded expanded polystyrene (XPS) low-density, Icynene loose-fill (pour-fill), Molded expanded polystyrene (EPS) high-density, Rice hulls, Fiberglass batts, Molded expanded polystyrene (EPS) low-density, Icynene spray, Open-cell polyurethane spray foam, Cardboard, Rock and slag wool batts, Cellulose loose-fill, Cellulose wet-spray, Rock and slag wool loose-fill, Fiberglass loose-fill, Polyethylene foam, Cementitious foam, Perlite loose-fill, Wood panels, such as sheathing, Fiberglass rigid panel, Vermiculite loose-fill, Vermiculite, Papercrete, Softwood, Wood chips and other loose-fill wood products, Aerated/cellular concrete (5% moisture), Styrofoam, fiberglass, gypsum, laminate, melamine, resin, Type X drywall, Type C drywall, wood, hardened plastic, or any combination thereof.

6. The block according to claim 1, wherein the at least one hollow pierces through the block.

7. The block according to claim 1, wherein the at least one hollow pierces the block perpendicularly to the finished face.

8. The block according to claim 1, wherein the at least one hollow is filled with a second material.

9. The block according to claim 8, wherein the second material is configured to provide an internal support structure.

10. The block according to claim 1, wherein the finish is decorative and/or protective.

11. The block according to claim 10, wherein the finish is heat resistant, fire resistant, fireproof, water resistant, dirt resistant, or any combination thereof.

12. The block according to claim 10, wherein the finish comprises ceramic tiles, paint, fiberglass, gypsum, laminate, melamine, resin, Type X drywall, Type C drywall, wood, aluminum, stainless steel, hardened plastic, cast iron, zinc alloy, tin, chrome, or any combination thereof.

13. A structure comprising a plurality of pre-finished, wherein each block comprises: a skeleton composed of a low density first material, wherein the skeleton includes at least one hollow; and a finish on at least one face of the block; and a support structure.

14. The structure according to claim 13, wherein the first material is heat resistant, fire resistant, fireproof, water resistant, or a combination thereof.

15. The structure according to claim 13, wherein the first material is a light weight thermally insulating material.

16. The structure according to claim 15, wherein the first material is selected from the group comprising: a hardened foam, polyurethane foam, phenolic foam, Polyisocyanurate spray foam, Closed-cell polyurethane spray foam, Phenolic spray foam, Urea-formaldehyde panels, Drywall, Urea foam, Extruded expanded polystyrene (XPS) high-density, Polystyrene board, Phenolic rigid panel, Urea-formaldehyde foam, High-density fiberglass batts, Extruded expanded polystyrene (XPS) low-density, Icynene loose-fill (pour-fill), Molded expanded polystyrene (EPS) high-density, Rice hulls, Fiberglass batts, Molded expanded polystyrene (EPS) low-density, Icynene spray, Open-cell polyurethane spray foam, Cardboard, Rock and slag wool batts, Cellulose loose-fill, Cellulose wet-spray, Rock and slag wool loose-fill, Fiberglass loose-fill, Polyethylene foam, Cementitious foam, Perlite loose-fill, Wood panels, such as sheathing, Fiberglass rigid panel, Vermiculite loose-fill, Vermiculite, Papercrete, Softwood, Wood chips and other loose-fill wood products, Aerated/cellular concrete (5% moisture), Styrofoam, fiberglass, gypsum, laminate, melamine, resin, Type X drywall, Type C drywall, wood, hardened plastic, or any combination thereof.

17. The structure according to claim 13, wherein the at least one hollow pierces through the pre-finished block.

18. The structure according to claim 13, wherein the at least one hollow pierces the pre-finished block perpendicularly to the finished face.

19. The structure according to claim 13, wherein the hollows of vertically and/or horizontally adjacent pre-finished blocks overlap at least in part.

20. The structure according to claim 13, wherein the support structure is an internal support structure, an external support structure, or both.

21. The structure according to claim 20, wherein the internal support is located within the hollows of the plurality of pre-finished blocks.

22. The structure according to claim 20, wherein the internal support structure comprises a second material.

23. The structure according to claim 22, wherein the second material is a filler.

24. The structure according to claim 20, wherein the internal support structure is a metal frame.

25. The structure according to claim 20, wherein the external support structure is a metal frame.

26. The structure according to claim 20, wherein the external support structure includes a retainer.

27. The structure according to claim 20, wherein the external support structure is located between and/or connected to vertically and/or horizontally adjacent blocks.

28. The structure according to claim 27, wherein the external support structure is selected from mortar, glue, frame, or any combination thereof.

29. A method of constructing a structure from pre-finished blocks, the method comprising: placing the pre-finished blocks in a required position; inserting at least one retainer; adding an internal support structure; adding an external support structure; and building further vertical and/or horizontal layers extending therefrom.

30. The method according to claim 29, wherein the pre-finished blocks are positioned such that at least one internal hollow of vertically and/or horizontally adjacent pre-finished blocks overlap at least in part.

31. The method according to claim 29, wherein the internal support structure is poured into the at least partially overlapping hollows.

32. The method according to claim 29, said positioning include stacking one of said pre-finished blocks onto another of said prefinished blocks.