US6298622B1 — Self-supporting construction element of expanded …

Claim 1

Independent Claim 90 words

A self-supporting construction element of expanded plastics, comprising: a) a central body, substantially parallelepipedic in shape, provided with opposite faces; b) at least one reinforcing section bar transversely extending across the central body between said opposite faces and embedded in the expanded plastics; and c) a first stretched mesh for supporting at least one layer of a suitable covering material, said stretched mesh being associated with a fin of said reinforcing section bar lying flush with and substantially parallel to at least one of the faces of said construction element.

Claim 2

Dependent Claim 90 words

A self-supporting construction element of expanded plastics, comprising: a) a central body, substantially parallelepipedic in shape, provided with opposite faces; b) at least one reinforcing section bar transversely extending across the central body between said opposite faces and embedded in the expanded plastics; and c) a first stretched mesh for supporting at least one layer of a suitable covering material, said stretched mesh being associated with a fin of said reinforcing section bar lying flush with and substantially parallel to at least one of the faces of said construction element.

Claim 3

Dependent Claim 25 words

Construction element according to claim 1 , wherein the reinforcing section bar is longitudinally extending within the central body along substantially the entire length thereof.

Claim 4

Dependent Claim 21 words

Construction element according to claim 1 , wherein the reinforcing section bar has a thickness of form 0.4 to 1.2 mm.

Claim 5

Dependent Claim 37 words

Construction element according to claim 1 , wherein the first stretched mesh for supporting at least one covering layer comprises opposite lateral portions lying at least in part flush with opposite lateral sides of the construction element.

Claim 6

Dependent Claim 24 words

Construction element according to claim 1 , wherein the stretched mesh essentially consists of a rhomb-shaped mesh having a length-to-height rhomb ratio of 2:1.

Claim 7

Dependent Claim 20 words

Construction element according to claim 1 , wherein the stretched mesh as a thickness of from 0.4 to 1.5 mm.

Claim 8

Dependent Claim 32 words

Construction element according to claim 1 , further comprising a layer of plaster, cement, or cement reinforced with fibers of s suitable fire-retarding or fire-resistant material, associated to the first stretched mesh.

Claim 9

Dependent Claim 23 words

Construction element according to claim 1 , wherein the reinforcing section bar transversely extends across the central body through the whole thickness thereof.

Claim 10

Dependent Claim 31 words

Construction element according to claim 8 , wherein the reinforcing section bar comprises a pair of opposite fins lying flush with and substantially parallel to the faces of the construction element.

Claim 11

Dependent Claim 38 words

Construction element according to claim 9 , further comprising a second stretched mesh for supporting at least one covering layer, the first and the second meshes being respectively associated to the opposite fins of the reinforcing section bar.

Claim 12

Dependent Claim 30 words

Construction element according to claim 9 , further comprising a rigid covering element associated to the reinforcing section bar at a side opposite with respect to the first stretched mesh.

Claim 13

Dependent Claim 31 words

Construction element according to claim 11 , wherein the rigid covering element is one of a panel of gypsum paperboard, wood, a rigid plastics, a decorating material, and a structural material.

Claim 14

Dependent Claim 25 words

Construction element according to claim 1 , wherein the reinforcing section bar is provided with a plurality of openings formed in a central portion thereof.

Claim 15

Dependent Claim 29 words

Construction element according to claim 13 , wherein the openings have a total area comprised between 10% and 60% of the overall surface areas of the reinforcing section bar.

Claim 16

Dependent Claim 23 words

Construction element according to claim 13 , wherein the openings have a circular cross-section with a diameter of from 15 to 150 mm.

Claim 17

Dependent Claim 28 words

Construction element according to claim 13 , wherein the openings are peripherally provided with a lip protruding from the central portion and fully embedded in the expanded plastics.

Claim 18

Dependent Claim 38 words

Construction element according to claim 13 , wherein the openings are provided with one or more protrusions being distributed around their peripheral edge and angularly offset from one another, the protrusions being fully embedded in the expanded plastics.

Claim 19

Independent Claim 126 words

A method of manufacturing a construction element according to any one of claims 1 - 17 , comprising the steps of: associating a stretched mesh for supporting at least one layer of a suitable covering material to a fin extending from one end of a reinforcing section bar; positioning the thus associated reinforcing section bar and stretched mesh into a molding seat of a suitable apparatus for molding plastics; feeding expandable plastics granules into the molding seat; and expanding and then boding together the plastics granules in the molding seat so as to embed the reinforcing section bar into a mass of expanded plastics having a predetermined shape and to maintain the stretched mesh at least in part substantially flush with the mass of expanded plastics.

Claim 20

Dependent Claim 23 words

A method according to claim 18 , wherein the stretched lath and the reinforcing section bar are associated with each other by welding.

Claim 21

Dependent Claim 29 words

The method according to claim 18 , wherein the stretched mesh is a stretched metallic lath essentially consisting of a rhomb-shaped mesh having a length-to-height rhomb ratio of 2:1.

Claim 22

Dependent Claim 27 words

A method according to claim 18 , further comprising an additional step of enucleating at least part of the stretched mesh from the mass of expanded plastics.

Claim 23

Dependent Claim 47 words

A method according to claim 21 , wherein the stretched mesh is enucleated from the mass of expanded plastics by means of a thermal treatment carried out by feeding onto the mass a sheet of warm air heated at a temperature of from 220° to 260° C.

Claim 24

Dependent Claim 27 words

A method according to claim 22 , wherein the thermal treatment is preceded by a step of scraping a skin layer off the mass of expanded plastics.

Claim 25

Independent Claim 127 words

A method of manufacturing a construction element according to any one of claims 1 - 17 , comprising the steps of: positioning a reinforcing section bar, provided with at least one fin at one end, into a molding seat of a suitable apparatus for molding plastics; feeding expandable plastics granules into the molding seat; expanding and then bonding together with plastics granules in the molding seat so as to embed the reinforcing section bar into a mass of expanded plastics having a predetermined shape and to maintain the at least one fin substantially flush with the mass of expanded plastics; and associating a stretched mesh for supporting at least one layer of a suitable covering material to the at least one fin of the reinforcing section bar.

Claim 26

Dependent Claim 30 words

A method according to claim 24 , further comprising an additional step of enucleating the at least one fin of the reinforcing section bar from the mass of expanded plastics.

Claim 27

Dependent Claim 49 words

A method according to claim 25 , wherein the at least one fin is enucleated from the mass of expanded plastics by means of a thermal treatment carried out by feeding onto the mass a sheet of warm air heated to a temperature of from 220° to 260° C.

Claim 28

Dependent Claim 158 words

A self-supporting construction element of expanded plastics, comprising: a) a central body, substantially parallelepipedic in shape, provided with opposite faces; b) a plurality of reinforcing section bars transversely extending across the central body between said opposite faces embedded in the expanded plastics; the reinforcing section bars being substantially Z-shaped and arranged in mirror image relationship about a longitudinal plane of symmetry of the construction element and comprising a central portion and a pair of respectively lower and upper fins extending perpendicularly in opposite directions from the ends of the central portion; at least one of said lower and upper fins lying flush with and substantially parallel to at least one of said opposite faces of the construction element; and c) a sheet-like member for supporting at least one layer of a suitable covering material associated to said at least one fin lying flush with and substantially parallel to at least one of the faces of said construction element.

Claim 29

Dependent Claim 158 words

A self-supporting construction element of expanded plastics, comprising: a) a central body, substantially parallelepipedic in shape, provided with opposite faces; b) a plurality of reinforcing section bars transversely extending across the central body between said opposite faces embedded in the expanded plastics; the reinforcing section bars being substantially Z-shaped and arranged in mirror image relationship about a longitudinal plane of symmetry of the construction element and comprising a central portion and a pair of respectively lower and upper fins extending perpendicularly in opposite directions from the ends of the central portion; at least one of said lower and upper fins lying flush with and substantially parallel to at least one of said opposite faces of the construction element; and c) a sheet-like member for supporting at least one layer of a suitable covering material associated to said at least one fin lying flush with and substantially parallel to at least one of the faces of said construction element.

Claim 30

Dependent Claim 46 words

A self-supporting construction element according to claim 27 , wherein said upper fin of the reinforcing section bar has a first portion, extending substantially perpendicularly to the central portion of the reinforcing section bar and a second end portion which is bent toward the central portion.

Claim 31

Dependent Claim 36 words

A self-supporting construction element according to claim 27 , wherein said upper fin of the reinforcing section bar extends from the central portion of the reinforcing section bar towards a lateral side of the construction element.

Claim 32

Dependent Claim 23 words

Construction element according to claim 27 , wherein the reinforcing section bar transversely extends across the central body through the whole thickness thereof.

Claim 33

Dependent Claim 25 words

Construction element according to claim 27 , wherein the reinforcing section bar is longitudinally extending within the central body along substantially the entire length thereof.

Claim 34

Dependent Claim 36 words

Construction element according to claim 27 , wherein the sheet-like member for supporting at least one covering layer comprises opposite lateral portions lying at least in part flush with opposite lateral sides of the construction element.

Claim 35

Dependent Claim 36 words

Construction element according to claim 27 , wherein the sheet-like member for supporting at least one covering layer is a stretched metallic lath essentially consisting of a rhomb-shaped mesh having a length-to-height rhomb ratio of 2:1.

Claim 36

Dependent Claim 25 words

Construction element according to claim 33 , further comprising a layer of plaster, cement or cement reinforced with fibers material, associated to the supporting lath.

Claim 37

Dependent Claim 25 words

Construction element according to claim 27 , wherein the reinforcing section bar is provided with a plurality of openings formed in a central portion thereof.

Claim 38

Dependent Claim 28 words

Construction element according to claim 35 , wherein the openings are peripherally provided with a lip protruding from said central portion and fully embedded in said expanded plastics.

Claim 39

Dependent Claim 38 words

Construction element according to claim 35 , wherein the openings are provided with one or more protrusions being distributed around their peripheral edge and angularly offset from one another, the protrusions being fully embedded in the expanded plastics.

Claim 40

Dependent Claim 32 words

Construction element according to claim 27 , wherein the reinforcing section bar comprises a pair of opposite fins lying flush with and substantially parallel to the opposite faces of the construction element.

Claim 41

Dependent Claim 37 words

Construction element according to claim 38 , further comprising a second lath for supporting at least one covering layer, the first and the second laths being respectively associated to the opposite fins of the reinforcing section bar.

Claim 42

Dependent Claim 25 words

Construction element according to claim 38 , further comprising a rigid covering element associated to the at least one fin of the reinforcing section bar.

Claim 43

Dependent Claim 25 words

Construction element according to claim 40 , wherein the rigid covering element is one of a panel of gypsum paperboard, wood, and a rigid plastic.

Claim 44

Dependent Claim 142 words

A construction assembly comprising: a plurality of element of expanded plastics arranged side-by-side, said element including: a) a central body, substantially parallelepipedic in shape, provided with opposite upper and lower faces and with opposite lateral sides; b) at least one reinforcing section bar transversely extending across the central body between said upper and lower faces and embedded in the expanded plastics; c) a sheet-like member for supporting at least one layer of a suitable covering material, said sheet-like member being associated to a fin of said reinforcing section bar lying flush with and substantially parallel to at least one of the faces of said construction element; a concrete casting housed in a cavity defined between said opposite lateral sides of adjacent element of said plurality of elements of expanded plastics; and means for stably anchoring the sheet-like member to said concrete casting.

Claim 45

Dependent Claim 142 words

A construction assembly comprising: a plurality of element of expanded plastics arranged side-by-side, said element including: a) a central body, substantially parallelepipedic in shape, provided with opposite upper and lower faces and with opposite lateral sides; b) at least one reinforcing section bar transversely extending across the central body between said upper and lower faces and embedded in the expanded plastics; c) a sheet-like member for supporting at least one layer of a suitable covering material, said sheet-like member being associated to a fin of said reinforcing section bar lying flush with and substantially parallel to at least one of the faces of said construction element; a concrete casting housed in a cavity defined between said opposite lateral sides of adjacent element of said plurality of elements of expanded plastics; and means for stably anchoring the sheet-like member to said concrete casting.

Claim 46

Dependent Claim 32 words

A construction assembly according to claim 42 , wherein said reinforcing section bar is longitudinally extending within said central body of the elements of expanded plastics along substantially the entire length thereof.

Claim 47

Dependent Claim 26 words

A construction assembly according to claim 42 , wherein said reinforcing section bar is provided with a plurality of openings formed in a central portion thereof.

Claim 48

Dependent Claim 50 words

A construction assembly according to claim 42 , wherein said means for stably anchoring the sheet-like member to the concrete casting comprises an end portion of the sheet-like member extending in a substantially vertical direction and lying partly flush with the opposite lateral sides of said elements of expanded plastics.

Claim 49

Dependent Claim 40 words

A construction assembly according to claim 45 , wherein said end portion of the sheet-like member extends flush with said element of expanded plastics within grooves longitudinally formed lengthwise in the opposite lateral sides of said elements of expanded plastics.

Claim 50

Dependent Claim 41 words

A construction assembly according to claim 42 , wherein said sheet-like member for supporting at least one layer of a suitable covering material is a stretched metallic lath essentially consisting of a rhomb-shaped mesh having a length-to-height rhomb ratio of 2:1.

Claim 51

Dependent Claim 26 words

A construction assembly according to claim 47 , further comprising a layer of plaster, cement, or cement reinforced with fiber material, associated to said sheet-like member.

Claim 52

Dependent Claim 32 words

A construction assembly according to claim 42 , wherein said elements of expanded plastics further comprise a pair of lugs laterally and longitudinally extending along the opposite sides of said central body.

Claim 53

Dependent Claim 23 words

A construction assembly according to claim 49 , further comprising a substantially mating joint for stably connecting side-by-side said elements of expanded plastics.

Claim 54

Dependent Claim 41 words

A construction assembly according to claim 50 , wherein said substantially mating joint comprises a groove and a rib of mating shape laterally formed in the lugs of the elements of expanded plastics and longitudinally extending along the full length thereof.

Claim 55

Dependent Claim 36 words

A construction assembly according to claim 49 , further comprising a plurality of reinforcing rods embedded in the concrete casting housed in the cavity defined between said opposite lateral sides of adjacent elements of expanded plastics.

Claim 56

Dependent Claim 31 words

A construction assembly according to claim 52 , further comprising means for supporting said plurality of reinforcing rods at a predetermined distance from the lugs of the elements of expanded plastics.

Claim 57

Dependent Claim 34 words

A construction assembly according to claim 53 , wherein said supporting means comprises a plurality of ribs extending from the lugs of the elements of expanded plastics and pitchwise arranged along the length thereof.

Claim 58

Dependent Claim 159 words

A construction assembly for erecting bearing and partition walls in a building comprising: a plurality of wall elements of expanded plastics arranged side-by-side, said elements including: a) a central body, substantially parallelepipedic in shape, provided with opposite upper and lower faces and with opposite lateral sides and with at least one cavity; b) at least one reinforcing section bar transversely extending across the central body between said upper and lower faces and embedded in the expanded plastics; c) a sheet-like member for supporting at least one layer of a suitable covering material, said sheet-like member being associated to a fin of said reinforcing section bar lying flush with and substantially parallel to at least one of the faces of said wall elements; and a concrete casting housed in the at least one cavity defined within the central body of said wall elements and between opposite lateral sides of adjacent elements of said plurality of wall elements of expanded plastics.

Claim 59

Dependent Claim 159 words

A construction assembly for erecting bearing and partition walls in a building comprising: a plurality of wall elements of expanded plastics arranged side-by-side, said elements including: a) a central body, substantially parallelepipedic in shape, provided with opposite upper and lower faces and with opposite lateral sides and with at least one cavity; b) at least one reinforcing section bar transversely extending across the central body between said upper and lower faces and embedded in the expanded plastics; c) a sheet-like member for supporting at least one layer of a suitable covering material, said sheet-like member being associated to a fin of said reinforcing section bar lying flush with and substantially parallel to at least one of the faces of said wall elements; and a concrete casting housed in the at least one cavity defined within the central body of said wall elements and between opposite lateral sides of adjacent elements of said plurality of wall elements of expanded plastics.

Claim 60

Dependent Claim 26 words

A construction assembly according to claim 55 , wherein said reinforcing section bar is provided with a plurality of openings formed in a central portion thereof.

Claim 61

Dependent Claim 22 words

A construction assembly as set forth in claim 55 , wherein said partition walls comprise at least one cavity filled with concrete.

Claim 62

Dependent Claim 30 words

A construction assembly according to claim 55 , wherein said sheet-like member is a stretched metallic lath essentially consisting of a rhomb-shaped mesh having a length-to-height rhomb ratio of 2:1.

Claim 63

Dependent Claim 26 words

A construction assembly according to claim 58 , further comprising a layer of plaster, cement, or cement reinforced with fiber material, associated to said sheet-like member.

Claim 64

Dependent Claim 24 words

A construction assembly according to claim 55 , wherein said reinforcing section bar transversely extends across said central body through the whole thickness thereof.

Claim 65

Dependent Claim 32 words

A construction assembly according to claim 60 , wherein said reinforcing section bar comprises a pair of opposite fins lying flush with and substantially parallel to the faces of said wall element.

Claim 66

Dependent Claim 36 words

A construction assembly according to claim 61 further comprising a pair of sheet-like members for supporting at least one covering layer, said sheet-like members being respectively associated to said opposite fins of the reinforcing section bar.

Claim 67

Dependent Claim 26 words

A construction assembly according to claim 61 , wherein said reinforcing section bar is longitudinally extending within said central body along substantially the entire length thereof.

Claim 68

Dependent Claim 30 words

A construction assembly according to claim 61 , further comprising a rigid covering element associated to said reinforcing section bar at a side opposite with respect to said sheet-like member.

Claim 69

Dependent Claim 26 words

A construction assembly according to claim 64 , wherein said rigid covering element is one of a panel of gypsum paperboard, wood, and a rigid plastic.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2004-10-08	2005-04-09	2005-10-09	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2008-10-08	2009-04-09	2009-10-09	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2012-10-08	2013-04-09	2013-10-09	$7700.00	Window Closed / Lapsed

Self-supporting construction element of expanded plastics, in particular for manufacturing floor elements and walls of buildings in general

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