PRECAST LIGHTWEIGHT CONCRETE COMPONENTS FOR OUTDOOR KITCHENS AND GRILL ISLANDS WITH ENHANCED ASSEMBLY AND DECORATIVE SYSTEMS
20260020670 ยท 2026-01-22
Inventors
Cpc classification
International classification
Abstract
The disclosure provides a novel approach to precast concrete components designed for outdoor kitchens and grill islands. By integrating Expanded Polystyrene (EPS) beads, composite fibers, and Fiber Reinforced Polymer (FRP) rebar into a concrete mix, a lightweight yet durable product is achieved. The alignment and assembly system utilizes composite pins and plates, facilitating precise and secure installation. Decorative features embedded within the concrete panels enhance aesthetic appeal. The disclosure addresses common issues related to weight, alignment, and durability, offering an improved solution for outdoor kitchen components.
Claims
1. A system of precast concrete components for outdoor kitchens and grill islands comprising one or more components formed from a concrete mix that includes Expanded Polystyrene (EPS), composite fibers, and Fiber Reinforced Polymer (FRP) rebar, aligned with a composite pin and plate assembly system for precise installation.
2. The system of precast concrete components of claim 1, wherein the concrete mix includes portland cement, sand, EPS beads, water, composite fibers, and FRP rebar in predetermined proportions, wherein said concrete mix is utilized to form the one or more components of said system of precast concrete components.
3. The system of precast concrete components of claim 1, wherein the composite pin and plate assembly system includes composite pins and plates that are configured for complementary alignment with at least one recess and associated hole defined on at least one or more components of said system of precast concrete components.
4. The system of precast concrete components of claim 1, wherein a bonding system uses one or more high-strength adhesive or mortar to secure the one or more components of said system of precast concrete components.
5. The system of precast concrete components of claim 1, wherein a bridging system is defined as a rabbeted bridge that is configured to reinforce one or more countertop sections.
6. The system of precast concrete components of claim 1, wherein at least one of the one or more components are defined as a panel, wherein the panel defines a recessed bottom edge to accommodate uneven floor surfaces, ensuring a level and stable installation.
7. The system of precast concrete components of claim 1, wherein decorative features including natural seashells, rocks, or gemstones are embedded in the concrete mix for enhanced aesthetic appeal.
8. The system of precast concrete components of claim 1, wherein at least one of the one or more components are defined as a panel, wherein the panel includes cast-in mesh vents for improved ventilation and cooling of said one or more components.
9. The system of precast concrete components of claim 1 wherein the manufacturing process includes custom molds for casting the components, vibrating to remove air pockets, and a curing process to ensure strength and durability.
10. A method of forming a system of precast concrete components comprising the steps of, providing cement, sand, EPS beads, composite fibers and water; mixing the cement, sand, EPS beads, composite fibers, and water to create a concrete mix; pouring the concrete mix into a mold and adding FRP Rebar; and curing one or more components that define a system of precast concrete components.
11. The method of claim 10, including the step of varying the proportion of cement, sand, EPS beads, composite fibers, and water in the concrete mix to alter a characteristic of the resulting one or more components.
12. The method of claim 10, including the step of varying the curing period of the concrete mix to alter a characteristic of the resulting one or more components.
13. The method of claim 10, including the step of vibrating the mold to remove air from the concrete mix.
14. The method of claim 10, including the step of utilizing a composite pin and plate assembly system to connect one or more components of the system of precast concrete components.
15. The method of claim 10, including the steps of providing one or more decorative features, and embedding the one or more decorative features in the concrete mix to enhance aesthetic appeal.
16. The method of claim 10, further comprising the step of forming a mesh vent in the one or more components for improved ventilation.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT AND OPERATION OF THE DISCLOSURE
[0038] Various exemplary embodiments of the present disclosure are described below. Use of the term exemplary means illustrative or by way of example only, and any reference herein to the disclosure is not intended to restrict or limit the disclosure to exact features or step of any one or more of the exemplary embodiments disclosed in the present specification. References to exemplary embodiment, one embodiment, an embodiment, various embodiments, and the like may indicate that the embodiment(s) of the disclosure so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily incudes the particular feature, structure, or characteristic. Further, repeated use of the phrase in one embodiment, in an exemplary embodiment, or in an alternative embodiment do not necessarily refer to the same embodiment, although they may.
[0039] It is also noted that terms like preferably, commonly, and typically are not utilized herein to limit the scope of the disclosure or to imply that certain features are critical, essential, or even important to the structure or function of the disclosure. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present disclosure.
[0040] The present disclosure is described more fully hereinafter with reference to the accompanying figures, in which one or more exemplary embodiments of the disclosure are shown. Like numbers used herein refer to like elements throughout. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be operative, enabling, and complete. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limited as to the scope of the disclosure, and any and all equivalents thereof. Moreover, many embodiments such as adaptations, variations, modifications, and equivalent arrangements will be implicitly disclosed by the embodiments described herein and fall within the scope of the instant disclosure.
[0041] Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for the purposes of limitation. Unless otherwise expressly defined herein, such terms are intended to be given their broad, ordinary, and customary meaning not inconsistent with that applicable in the relevant industry and without restriction to any specific embodiment hereinafter described. As used herein, the article a is intended to include one or more items. Where only one item is intended, the terms one and only one, single, or similar language is used. When used herein to join a list of items, the term or denotes at least one of the items but does not exclude a plurality of items of the list.
[0042] For exemplary methods or processes of the disclosure, the sequence and/or arrangement of steps described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal arrangement, the steps of any such processes or methods are not limited to being carried out in any particular sequence or arrangement, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and arrangements while still falling within the scope of the present disclosure.
[0043] Additionally, any references to advantages, benefits, unexpected results, or operability of the present disclosure are not intended as an affirmation that the disclosure has previously been reduced to practice or that any testing has been performed. Likewise, unless stated otherwise, use of verbs in the past tense (present perfect or preterit) is not intended to indicate or imply that the disclosure has previously been reduced to practice or that any testing has been performed.
[0044] For a better understanding of the disclosure and its operation, turning now to the drawings,
[0045] In accordance with another embodiment, the concrete mix comprises portland cement in a range measuring approximately between 12.04 to 15.48 mass %, sand in a range measuring approximately between 32.12 to 41.30 mass %, EPS beads in a range measuring approximately between 32.12 to 41.30 mass %, water in a range measuring approximately between 11.22 to 14.42 mass %, and composite fibers in a range measuring approximately between 0.62 to 0.87 mass %. This concrete mixture further comprises FRP Rebar provided in #3 and #4 sizes.
[0046] While similar formulations, ingredients, and amounts may be effective (and thus considered within the scope of this disclosure), the following concrete mix has experimentally proven to be optimal, and thus a preferred embodiment of the concrete mix comprises portland cement of about 13.76 mass % (+/0.5%), sand of about 36.71 mass % (+/0.5%), EPS beads of about 36.71 mass %, water of about 12.82 mass % (+/0.5%), composite fibers of about 0.25% mass % (minimum) (+/0.5%), and FRP Rebar in #3 or #4 sizes.
[0047] In order to form one or more embodiments of the system of precast construction components 10 using one of the preferred concrete mixtures, the portland cement, sand, EPS beads, composite fibers, and water are combined in a preselected vessel (not shown) and mixed to achieve the desired consistency. The mixture is then introduced to a mold configured (i.e. sized, shaped, and otherwise intended) to shape the concrete mixture into the desired geometry. The FRP Rebar is added to the concrete mixture, and the molds are bounced, shaken, or otherwise vibrated to remove any undesirable air pockets. Any desirable decorative elements intended to be positioned on the facia may be added to the concrete mixture at this point as well. The concrete mixture in the molds may then be permitted to cure for approximately three hours, at a temperature of at least 40 F. (4 C.). In the preferred method of manufacture, the cured mixture may be removed from the molds following the three hour cure, but preferably is allowed to cure for up to four weeks before being deployed as a construction component.
[0048] The following is an exemplary method of forming one or more embodiments of the preferred concrete mixture. Loading twenty (20) gallons of EPS beads in a mixing container and powering on a mixing element. While mixing, spray approximately one and a half to two (1.5-2.0) gallons of water over the blending EPS beads, blending for about two (2) minutes. Adding ten (10) gallons of sand and an additional one (1) gallon of water. Adding another ten (10) gallons of sand, along with another approximately one (1) gallon a water, continuing to blend the mixture for one to two (1-2) minutes. Adding about ninety four (94) pounds of cement (+/1.0 lbs) and approximately 2.5 gallons of water (bringing the approximate amount of total water to roughly 6-6.5 gallons total) and blending for five minutes, or until such time as the mixture is homogeneous throughout. The mixture is then poured into a mold of predetermined size and shape, filling the mold cavity to a depth of half an inch, shaking or vibrating the mold as the mixture is poured into the mold to reduce or eliminate any air pockets. Distributing approximately two pounds of polymeric fibers throughout the mold, focusing on inner corners, edges, and anticipated stress points. Inserting FRP rebar, taking care to maintain -1 inch of coverage with the concrete mixture. Filling the remaining mold void, continuing to shake or vibrate the mold while doing so. Covering the mold exterior surface, preferably with a moisture impervious vapor barrier so as to maintain moisture for at least twenty-four to forty-eight (24-48) hours. Finally, either with or without the cover, continue curing the mixture in the mold for seven (7) days minimum.
[0049] The following is an alternative, exemplary method of forming one or more embodiments of the preferred concrete mixture. Loading the ten to twelve (10-12) gallons of EPS beads in a mixing container and powering on a mixing element. While mixing, spraying approximately one and a half to two (1.5-2.0) gallons of water over the blending EPS beads, blending for about two (2) minutes. Adding ten (10) gallons of sand and an additional one (1) gallon of water. Adding another ten (10) gallons of sand, along with another approximately one (1) gallon a water, continuing to blend the mixture for one to two (1-2) minutes. Adding about ninety four (94) pounds of cement (+/1.0 lbs) and approximately two and half (2.5) gallons of water (bringing the approximate amount of total water roughly 6-6.5 gallons total) and blending for five minutes, or until such time as the mixture is homogeneous throughout. The mixture is then poured into a mold of predetermined size and shape, filling the mold cavity to a depth of half an inch, shaking or vibrating the mold as the mixture is poured into the mold to reduce or eliminate any air pockets. Distributing approximately two pounds of polymeric fibers throughout the mold, focusing on inner corners, edges, and anticipated stress points. Inserting FRP rebar, taking care to maintain one (1) inch of coverage with the concrete mixture. Filling the remaining mold void, continuing to shake or vibrate the mold while doing so. Covering the mold exterior surface, preferably with a moisture impervious vapor barrier so as to maintain moisture for at least forty-eight to seventy-two hours (48-72) hours. Finally, either with or without the cover, continue curing the mixture in the mold for seven (7) days minimum, but preferably up to twenty-eight days for maximum strength.
[0050] The following is another alternative, exemplary method of forming one or more embodiments of the preferred concrete mixture. Loading six to eight gallons of EPS beads in a mixing container and powering on a mixing element. While mixing, spraying approximately one (1) gallon of water over the blending EPS beads, blending for about two (2) minutes. Adding ten (10) gallons of sand and an additional 0.8 gallons of water. Adding another ten (10) gallons of sand, along with another approximately one (1) gallon a water, continuing to blend the mixture for one to two (1-2) minutes. Adding about ninety four (94) pounds of cement (+/1.0 lbs) and approximately three (3) gallons of water (bringing the approximate amount of total water to roughly 5.8 gallons total) and blending for five (5) minutes, or until such time as the mixture is homogeneous throughout. The mixture is then poured into a mold of predetermined size and shape, filling the mold cavity to a depth of half an inch, shaking or vibrating the mold as the mixture is poured into the mold to reduce or eliminate any air pockets. Distributing approximately two (2) pounds of polymeric fibers throughout the mold, focusing on inner corners, edges, and anticipated stress points. Inserting FRP rebar, taking care to maintain three quarters to one (-1) inch of coverage with the concrete mixture. Filling the remaining mold void, continuing to shake or vibrate the mold while doing so. Covering the mold exterior surface, preferably with a moisture impervious vapor barrier so as to maintain moisture for at least forty-eight to seventy-two hours (48-72) hours. Finally, either with or without the cover, continue curing for seven (7) days minimum, but preferably up to twenty-eight (28) days for maximum strength.
[0051] The following is a further alternative, exemplary method of forming one or more embodiments of the preferred concrete mixture. Loading sixteen (16) gallons of EPS beads in a mixing container and powering on a mixing element. While mixing, spraying approximately one and a half to two gallons of water over the blending EPS beads, blending for about two (2) minutes. Adding ten (10) gallons of fine mortar sand and an additional one (1) gallon of water. Adding another ten (10) gallons of mortar sand, along with another approximately one (1) gallon a water, continuing to blend the mixture for one to two (1-2) minutes. Adding about ninety four (94) pounds of cement (+/1.0 lbs) and approximately two and half (2.5) gallons of water (bringing the approximate amount of total water to roughly 6-6.5 gallons total) and blending for five (5) minutes, or until such time as the mixture is homogeneous throughout. The mixture is then poured into a mold of predetermined size and shape, filling the mold cavity to a depth of half an inch, shaking or vibrating the mold as the mixture is poured into the mold to reduce or eliminate any air pockets. Distributing approximately two (2) pounds of polymeric fibers throughout the mold, focusing on inner corners, edges, and anticipated stress points. Inserting FRP rebar, taking care to maintain three quarter to one (-1) inch of coverage with the concrete mixture. Filling the remaining mold void, continuing to shake or vibrate the mold while doing so. Covering the mold exterior surface, preferably with a moisture impervious vapor barrier so as to maintain moisture for at least forty-eight to seventy-two hours (48-72) hours. Finally, either with or without the cover, continue curing the mixture in the mold for seven days minimum, but preferably up to twenty-eight days for maximum strength.
[0052] As would be understood by one of ordinary skill in the relevant art, any appropriate size and shape of component may be molded using the aforementioned manufacturing process. However, it is particularly desirable to form one or more post(s) 11, front panel(s) 12, back panel(s) 13 and end panels(s) 14. In one embodiment, each of these components are generally rectangular in shape. In the preferred embodiment, post 11 defines an elongated cuboidal geometry with a substantially square cross-sectional shape (best seen in
[0053] In the preferred embodiment, end panel 14 defines a generally rectangular shape, and further ideally includes one or more channels 21 extending longitudinally along a length of end panel 14 as seen in
[0054] Throughout the present disclosure, reference is made to a range of acceptable fasteners that may be deployed in securing the various components of the preferred system of precast concrete construction components 10 to one another. While it would be understood to one of ordinary skill in the art that other suitable fasteners may be deployed in connection with said system of precast concrete construction components, a preferred embodiment of fasteners used in connection with said system of precast concrete construction components are formed from a composite material. In one embodiment, one or more pins 17 are defined as -inch to -inch FRP pins, defining a rod-like size and shape, while defining a length measuring 1 inches to 6 inches. Similarly, an embodiment of said system of precast concrete construction components 10 preferably includes one or more plates 26. Preferred one or more plates 26 are defined as -inch to -inch thick, with alignment pin holes 26A formed therein complementary to the size, shape, and geometry to pins 17. These pins 17 and plates 26 are adapted to be complementary to the recesses 16 and pin holes 25 or grooves 27, 28 and cavities 29, 30 formed in other components of the preferred embodiment(s) of said system of precast concrete construction components 10 such as seen in
[0055] Similarly, while it would be understood to one of ordinary skill in the art that certain adhesives may be deployed in connection with said system of precast concrete construction components 10, one or more preferred embodiment(s) of an adhesive such as adhesive 60 (
[0056] The selection of adhesive is no mere design choice, as the preferred adhesives listed above have been specifically chosen because they demonstrate high bond strength, weather resistance, flexibility, ease of application and gap filing, versatility, durability, and define a quick setting speed in the intended operating environment of one or more embodiments of preferred system of precast concrete construction components 10. Similarly, while it would be understood to one of ordinary skill in the art that certain mortars may be deployed in connection with said system of precast concrete construction components 10, the preferred embodiment of mortar used in connection with said system of precast concrete construction components 10 is ASTM C270 Type N Mortar. This mortar has been determined to provide enhanced bonding strength and durability suitable for long life in outdoor environments, it demonstrates good workability and adhesion, balanced strength and flexibility, and is suitable for areas exposed to moisture and variable weather conditions. In one or more alternative embodiments of system of precast concrete construction components 10, additional bonding may be achieved through the use of other acceptable mortars or polyurethane foam adhesive.
[0057] As described throughout and illustrated in the figures (most noticeably in
[0058] As described throughout this disclosure and illustrated most prominent in
[0059] An alternative embodiment of a system of precast construction components 10 is demonstrated by top and bottom views in
[0060] Benefits of the system of precast concrete construction components 10 have been demonstrated to include up to 50% weight reduction compared to traditional concrete, resulting in up to 40% decrease in transportation costs and reduced installation costs. Additionally, composite materials are corrosion resistant, avoids internal pressures that lead to spalling, provide a 25% increase in durability over conventional metal components, and significantly extend the lifespan of outdoor kitchen elements.
[0061] The illustrations and examples provided herein are for explanatory purposes and are not intended to limit the scope of the appended claims. Attached hereto and submitted herewith as a part of this application is an Appendix to the Specification, which includes digital images 1-88 demonstrating various embodiments of outdoor kitchen configurations formed from the system of precast construction components 10 according to the present disclosure created by the inventor. In some of the images, various accessories that may be utilized in an outdoor kitchen are shown connected to the system of precast construction components 10. All parts, portions, elements, and/or combinations of the designs as shown in the Figures in the Specification and Appendix images 1-88 are to be considered as part of the disclosure.