"COMPOSITE ROOF INSULATION BLOCK"
Field of the invention
The present invention relates to the manufacture and design construction of a composite roof insulation block which offer excellent thermal insulation and a finished roof tile in one composite element.
Background of the Invention
US4191001 relates to a method of reinsulating concrete block buildings in which the exterior of the cement block structure is first furred out vertically to which high density polystyrene board is applied horizontally and the edges of the styrene board is glued. Subsequently, a polymerically bonded concrete mixture is applied to the exterior surface to bond the polymerically bonded concrete mixture to the childen wire and the exterior of the styrene board to form a strong shell with a thermal barrier capable of substantially saving on heat loss of the home.
US7509779 relates to a lightweight foam building block useful in construction walls of buildings. The block is made from rigid foams in which the foam blocks are connected in a particular way. The lightweight foam building block of US7509779 comprises of a outer body constructed of at least a first rigid foam member and at least a second rigid foam member; and at least one cross-member assembly comprising a rigid reinforcing material sandwiched between two rigid foam cross-member sections.
US7188455 relates to a roofing element comprising a structural box of concrete and an insulating layer extending inside the structural box. US7188455 relates to the roofing elements having structural box of concrete having insulating layer inside it wherein the structural box is having longitudinal pre-stressed elements of one or more to provide support.
Summary of the invention
Buildings are made of concrete which is a good conductor of heat. About 70% of total heat in a building is passed through the roof. In summers, the buildings are heated and in winters, the buildings are cooled due to the transfer of heat through

concrete. The conductance of heat through concrete can be prevented by insulating the roof from the exterior. This helps in large savings in energy cost in air conditioning and also increases comfort levels.
Extruded polystyrene board (XPS) is well established as a long term durable insulating medium for the exterior of buildings. It has minimal water absorption and capillarity, which does not allow the absorption of water over a period of time. XPS has good compressive strength properties. The XPS board being a good insulating medium cannot be left exposed to the sun as it gets deteriorated when exposed to UV rays. It easily catches fire and gets easily dissolved in solvents. It has low point impact resistance. Hence, it is essential to protect the extruded polystyrene board.
The insulating boards are made up of extruded polystyrene boards (XPS) and are spread over the water proofed concrete surface. A geotextile membrane is spread on top of the board. A layer of cement sand mortar (Screed) is spread over the geotextile membrane in a thickness of 15-30 cm or more. The cement mortar is then covered with a tile. The conventional process of producing the insulation board has a number of limitations and disadvantages. There are a number of limitations and disadvantages associated with the insulating boards known in the art which include: the process is multilayered, results in additional of more dead load to the building, more expensive and time consuming, requires the services of a skilled contractor who will execute the job and inn constructed buildings, the insulation cannot be done without dismantling the existed roof covering.
The other product available for insulating buildings includes an insulating board made up of extruded polystyrene board (XPS) with a concrete coating on top. However, these insulating boards for buildings also have a number of disadvantages that include: the block has to be laid loose over the roof; the XPS board is exposed from bottom which is subject to damage by fire or impact and the damage to the board due to the coaltar waterproofing coating over the roof.
An insulating board with a layer of modified insulating concrete at top, bottom & sides around the XPS board is known in the art. However, the disadvantage of such an insulating board is that the side walls of the concrete acts as thermal bridges and conducts the heat across them and therefore do not provide 100% insulation.

An insulating board for a building roof made up of concrete on top and bottom but no sidewalls are known in the art. However, the disadvantage of such an insulating board that the top and bottom surfaces were susceptible for delamitation.
Hence, it is extremely important to provide an encapsulating layer of modified insulating concrete that would provide a tough durable medium and at the same time would protect the XPS board.
Brief description of the drawings
Figure 1 (a): Composite insulation wall panel Figure 1 (b): Composite insulation roof block
101- Top of the composite insulation block made up of modified concrete mixture,
102- Extruded polystyrene board, 103- Bottom of the composite insulation block made up of modified concrete mixture, 104- Pillar of the composite insulation block made up of modified concrete mixture
Detailed description of the present invention
The present invention relates to the manufacture and design construction of a composite roof insulation block which offer excellent thermal insulation and a finished roof tile in one composite element.
An encapsulating layer of modified insulating concrete provides a tough durable medium and protects the extruded polystyrene board (XPS) board by supplementing the top and bottom with the pillars on all the sides of the block; wherein the top, bottom and pillars of the said block is made up of concrete.
The pillars on the four sides of the block not only provide strength and durability to the block but also reduce the thermal bridge.
The composition of the modified concrete mix comprises: ordinary portland cement, silica quartz aggregates, perlite, super plasticizers, polymer, synthetic inorganic iron oxide pigments and potable water. The said ingredients are mixed in various ratios and proportions and are experimentally tested to identify the concrete mixture with optimum durability strength. The ingredients mixed in various proportions and ratios are provided in Table 1.

Table 1: Composition of the modified concrete mixture

(Table Removed)
In an embodiment of the invention, a composite insulation block composed of a modified concrete mixture; wherein said composite insulation block comprises of a top, bottom and rectangular pillars placed longitudinally at each corner and/or middle of said block. The insulating material is sandwiched between the concrete layers positioned at the top, bottom and the rectangular pillars placed longitudinally at each corner and/or middle of said composite insulation block. The composite insulation block is useful for the construction of walls and/or ceilings to provide insulation to the buildings from the external environment.
In another embodiment of the invention, the insulating material fastened between the concrete layers of the composite insulation block is selected from extruded polystyrene or polyurethane.
In still another embodiment of the invention, the insulating material sandwiched between the concrete layers of the composite insulation block is extruded polystyrene.

In yet another embodiment of the invention, the top concrete layer of said composite insulation block is coated with an acrylic coating or a polyurethane coating.
In an embodiment of the invention, the top layer, the bottom layer and the pillars of said composite insulation block is composed of a modified concrete mixture wherein the modified concrete mix comprises of ordinary portland cement, silica quartz aggregates, perlite, super plasticizers, polymer, synthetic inorganic iron oxide pigments and potable water.
In another embodiment of the invention, the modified concrete mixture comprises of portland cement, silica quartz aggregates and perlite present in the ratio of 1: 1.5-1.0: 0.5-1.0 by volume and 0.1-2.0 % of plasticizer by weight of portland cement, 2.0-7.0 % of polymer by weight of portland cement and 0.1-2.0 by % of synthetic inorganic iron oxide pigments by weight of portland cement. The potable water used for the preparation of the modified concrete mixture is present in waterxement ratio that ranges from 0.35 to 0.45. The concrete mixture with optimum durability strength was identified with the formula A as specified in Table 1.
In still another embodiment of the invention, the super plasticizer used in the preparation modified concrete mixture is either TAMOL (BASF) or GLENIUM (BASF).
In yet another embodiment of the invention, the polymers used in the preparation of modified concrete mixture are styrene acrylic I copolymers and 100% acrylic polymers (BASF and Rohm & Hass). The synthetic inorganic pigment used in the preparation of modified concrete mixture is yellow synthetic iron oxide pigment (manufactured by Bayer).
The present invention is now described in more detail by reference to the following examples, but it should be understood that the invention is not construed as being limited thereto.
EXAMPLES
Example 1: Preparation of the modified concrete mix
The combinations A, B, C, D, E and F are experimentally tested using the ingredients in the proportions as provided in table 1. All the ingredients viz.

ordinary portland cement, silica quartz aggregates, perlite, super plasticizers, polymer, synthetic inorganic iron oxide pigments and potable water are mixed in specific proportions (as defined in Table 1) in a sigma blade mixer for 10-20 minutes at room temperature. The modified concrete is made to a pourable consistency and is used for the preparation of the board.
Example 2: Preparation of the board of modified concrete mix (Size 300x300x70 mm)
A rubber / PVC mould is taken wherein the modified concrete mix is poured in the mould at room temperature in a layer of 10mm thickness. The mould is vibrated for the modified concrete mix to settle down and all air to be excluded. Subsequently, a pre cut Extruded Polystyrene board (50mm thick) of density 32kg/m3 is placed over the concrete layer. The board is placed on the modified concrete which is again poured to fill the mould completely so that the extruded polystyrene board is covered completely on both sides by a layer of at least 10mm. The mould is then stored at room temperature and humidity for 24 hrs, after which the cast material is demoulded and air cured at room temperature for 7 days. Finally, the product is coated on top with a solvent based transparent acrylic coating to provide the finished product.
Example 3: Preparation of the board of modified concrete mix (600x600x95 mm)
A fiber glass mould of size 600x600x95 mm is taken wherein the modified concrete mix is poured in a layer of 10mm thickness. An extruded polystyrene board of 75mm thickness and density 32kg/m3 is placed over the modified concrete layer. The board is then covered with more layers of modified concrete. The mould is vibrated and left at room temperature for 24 hrs. The next day the cast product is demoulded and air cured for 7 days.
Example 4: Preparation of a finished tile
A composite insulation block as obtained from examples 2 or 3, the top surface of the composite insulation block is spray coated with a 100% acrylic polymer emulsion to obtain a finished tile.

I CLAIM;
1. A composite insulation block composed of a modified concrete mixture; wherein said composite insulation block comprises of a top, bottom and rectangular pillars placed longitudinally at each corner and/or middle of said composite insulation block; wherein an insulating material is sandwiched between the concrete layers positioned at the top, bottom and the rectangular pillars placed longitudinally at each corner and/or middle of said composite insulation_block.
2. A composite insulation block as claimed in claim 1, wherein the insulating material is extruded polystyrene or polyurethane.
3. A composite insulation block as claimed in claim 2, wherein the insulating material is extruded polystyrene.
4. A composite insulation block as claimed in claim 1, wherein the top concrete layer is coated with an acrylic coating or a polyurethane coating.
5. A composite insulation block as claimed in claim 1, wherein the modified concrete mix comprises of ordinary portland cement, silica quartz aggregates, perlite, super plasticizers, polymer, synthetic inorganic iron oxide pigments and potable water.
6. A composite insulation block as claimed in claim 5, wherein the portland cement, silica quartz aggregates and perlite are present in the ratio of 1: 1.5-1.0: 0.5-1.0 by volume.
7. A composite insulation block as claimed in claim 5, wherein percentage of super plasticizers is 0.1-2.0 % by weight of portland cement.
8. A composite insulation block as claimed in claim 5, wherein percentage of polymer is 2.0-7.0 % by weight of portland cement.
9. A composite insulation block as claimed in claim 5, wherein percentage of synthetic inorganic iron oxide pigments is 0.1-2.0 by % weight of portland cement.
10. A composite insulation block as claimed in claim 1, wherein said block is used for the construction of walls and/or roof tops for providing insulation to the buildings from the external environment.
11. A composite insulation block substantially as herein described with reference to the foregoing description, examples, tables and the accompanying drawings.