Structural building element

Claim 2

A building element having a high structural load bearing capacity and comprising: a. a continuous phase of cementitious material, wherein said continuous phase includes: b. an interconnected matrix in the form of a cellular structure and having a first density, and c. a plurality of zones dispersed within the matrix having a second density lower than the first density, wherein the matrix comprises a plurality of wall sections substantially completely surrounding the lower density zones with at least one portion of the matrix disposed interiorly of the element between said low density zones for interconnecting opposed wall sections of the matrix, and d. a common cementitious bond between the wall sections of the matrix, the interiorly disposed interconnecting portion of the matrix, and the lower density zones for producing a synergistic relationship imparting increased compressive strength and minimization of fracture propagation throughout the element.

Claim 3

The element of claim 1 wherein each lower density zone includes at least one void formed therein.

Claim 4

The element of claim 1 wherein the matrix includes reinforcing members embedded therein.

Claim 5

The element of claim 1 wherein: a. the first density is of a range from about 60 to 200 pounds per cubic foot, and b. the second density is of a range of from about 10 to 50 pounds per cubic foot.

Claim 6

The element of claim 1 wherein the overall average density of the element is of an inclusive range from about 20 to 200 pounds per cubic foot.

Claim 7

The element of claim 1 wherein: a. the matrix has a composition including a continuous phase of cementitious material and a first discontinuous phase selected from the group consisting of aggregate particles, organic fibers, inorganic fibers and mixtures thereof, and b. each lower density zone has a composition including a continuous phase of cementitious material and a second discontinuous phase of a filler having a density lower than the density of the cementitious material.

Claim 8

The element of claim 6 wherein the filler is selected from the group consisting of perlite, vermiculite, expandable polymers and mixtures thereof.

Claim 9

The element of claim 7 wherein: a. the interconnected matrix has a density inclusive of the range of 90 to 150 pounds per cubic foot and the first discontinuous phase is aggregate, and b. each lower density zone has a density inclusive of the range of 22-36 pounds per cubic foot and the second discontinuous phase is perlite.

Claim 10

The element of claim 1 wherein: a. the element is of substantially rectangular configuration, and b. the lower density zones are defined by substantially rectangular-shaped blocks.

Claim 11

The element of claim 9 wherein each rectangular-shaped block is provided with at least one groove along a side thereof.

Claim 12

The elements of claim 1 wherein the element is of a substantially planar configuration with: a. the portion of the matrix forming one face including a discontinuous phase selected from the group consisting of organic fibers, inorganic fibers and mixtures thereof, and b. the portion of the matrix forming the opposing face including a discontinuous phase of aggregate particles.

Claim 13

The building element of claim 1 wherein: a. the interconnected matrix has a density in the range of from about 60 to 200 pounds per cubic foot and includes: 1. a continuous phase of cementitious material, and 2. a first discontinuous phase selected from the group consistng of aggregate particles, organic fibers, inorganic fibers and mixtures thereof; and b. each of the lower density zones has a density in the range of from about 10 to 50 pounds per cubic foot, with each lower density zone including: 1. a continuous phase of cementitious material, and 2. a second discontinuous phase of a filler selected from the group consisting of perlite, vermiculite, expandable polymers and mixture thereof.

Claim 14

The element of claim 12 wherein a. the element is of substantially rectangular configuration, and b. the lower density zones are defined by substantially rectangular-shaped blocks with each block having at least one void formed therein.

Claim 15

The element of claim 13 wherein a. the overall average density of the element is of and inclusive range from about 20 to 200 pounds per cubic foot, and b. the matrix includes reinforcing members embedded therein.

Claim 16

The element of claim 12 wherein: a. the element has a substantially circular cross-sectional configuration, and b. each zone has a substantially arcuate configuration.

Claim 17

A building element having a substantially elongate configuration and comprising: a. a continuous phase of cementitious material, wherein said continuous phase includes: b. an interconnected matrix having a first density, wherein a portion of the matrix is disposed substantially along the longitudinal axis of the cement, and c. a plurality of zones dispersed within the matrix having a second density lower than the first density.

Claim 18

A building element having a substantially elongate configuration and comprising: a. a continuous phase of cementitious material, wherein said continuous phase includes: b. an interconnected matrix having a first density, wherein a portion of the matrix is disposed substantially along the longitudinal axis of the cement, and c. a plurality of zones dispersed within the matrix having a second density lower than the first density.

Claim 19

The element of claim 16 wherein: a. the element has a substantially circular cross-sectional configuration, and b. each zone has a substantially arcuate configuration.

Claim 20

The element of claim 17 wherein the zones are spaced along a series of tiers with wall sections of matrix separating adjacent zones.

Claim 21

A building element having a planar configuration and comprising: a. a continuous phase of cementitious material, wherein said continuous phase includes: b. an interconnected matrix having a first density, wherein the matrix includes at least three spaced continuous layers extending to the longitudinal and transverse extremities of the element, and c. a plurality of zones dispersed within the matrix having a second density lower than the first density.

Claim 22

A building element having a planar configuration and comprising: a. a continuous phase of cementitious material, wherein said continuous phase includes: b. an interconnected matrix having a first density, wherein the matrix includes at least three spaced continuous layers extending to the longitudinal and transverse extremities of the element, and c. a plurality of zones dispersed within the matrix having a second density lower than the first density.

Claim 23

A building element comprising: a. a continuous phase of cementitious materials, wherein said continuous phase includes: b. an interconnected matrix having a first density, wherein a portin of the matrix is disposed along the geometric central region of the element, and c. a plurality of zones dispersed within the matrix having a second density lower than the first density.

Claim 24

A building element comprising: a. a continuous phase of cementitious materials, wherein said continuous phase includes: b. an interconnected matrix having a first density, wherein a portin of the matrix is disposed along the geometric central region of the element, and c. a plurality of zones dispersed within the matrix having a second density lower than the first density.

Claim 25

A building element comprising: a. a continuous phase of cementitious material, wherein said continuous phase includes: b. an interconnected matrix in the form of a cellular structure and having a density in the range of from about 60 to 200 pounds per cubic foot, which matrix includes: 1. a continuous phase of cementitious material, and 2. a first discontinuous phase selected from the group consisting of aggregate particles, organic fibers, inorganic fibers and mixtures thereof; and c. a plurality of zones having a density in the range of from about 10 to 50 pounds per cubic foot dispersed within and surrounding by the matrix, each of which zones includes: 1. a continuous pase of cementitious material, and 2. a second discontinuous phase of a filler selected from the group consisting of perlite, vermiculite, expandable polymers and mixtures thereof; wherein the zones are spaced along a series of tiers with wall sections of matrix separating adjacent zones and the common cementitious bond between the matrix and the lower density zones produces a synergistic relationship for imparting increased compressive strength and minimization of fracture propagation throughout the element.

Claim 26

A building element comprising: a. a continuous phase of cementitious material, wherein said continuous phase includes: b. an interconnected matrix in the form of a cellular structure and having a density in the range of from about 60 to 200 pounds per cubic foot, which matrix includes: 1. a continuous phase of cementitious material, and 2. a first discontinuous phase selected from the group consisting of aggregate particles, organic fibers, inorganic fibers and mixtures thereof; and c. a plurality of zones having a density in the range of from about 10 to 50 pounds per cubic foot dispersed within and surrounding by the matrix, each of which zones includes: 1. a continuous pase of cementitious material, and 2. a second discontinuous phase of a filler selected from the group consisting of perlite, vermiculite, expandable polymers and mixtures thereof; wherein the zones are spaced along a series of tiers with wall sections of matrix separating adjacent zones and the common cementitious bond between the matrix and the lower density zones produces a synergistic relationship for imparting increased compressive strength and minimization of fracture propagation throughout the element.

Claim 27

A building element having a planar configuration and comprising: a. a continuous phase of cementitious material, wherein said continuous phase includes: b. an interconnected matrix in the form of a cellular structure and having a density in the range of from about 60 to 200 pounds per square foot, which matrix includes: 1. a continuous phase of cementitious material, 2. a first discontinuous phase selected from the group consisting of aggregate particles, organic fibers, inorganic fibers and mixtures thereof; and 3. at least three spaced continuous layers extending to the longitudinal and transverse extremities of the element; and c. a plurality of zones having a density in the range of from about 10 to 50 pounds per cubic foot dispersed within one surrounded by the matrix, each of which zones includes: 1. a continuous phase of cementitious material, and 2. a second discontinous phase of filler selected from the group consisting of perlite, vermiculite, expandable polymers and mixtures thereof; wherein the common cementitious bond between the matrix and lower density zones produces a synergistic relationship for imparting increased compressive strength and minimization of fracture propagation throughout the element.

Claim 28

A building element having a planar configuration and comprising: a. a continuous phase of cementitious material, wherein said continuous phase includes: b. an interconnected matrix in the form of a cellular structure and having a density in the range of from about 60 to 200 pounds per square foot, which matrix includes: 1. a continuous phase of cementitious material, 2. a first discontinuous phase selected from the group consisting of aggregate particles, organic fibers, inorganic fibers and mixtures thereof; and 3. at least three spaced continuous layers extending to the longitudinal and transverse extremities of the element; and c. a plurality of zones having a density in the range of from about 10 to 50 pounds per cubic foot dispersed within one surrounded by the matrix, each of which zones includes: 1. a continuous phase of cementitious material, and 2. a second discontinous phase of filler selected from the group consisting of perlite, vermiculite, expandable polymers and mixtures thereof; wherein the common cementitious bond between the matrix and lower density zones produces a synergistic relationship for imparting increased compressive strength and minimization of fracture propagation throughout the element.