Static structures (e.g. – buildings) – Processes – Filling preformed cavity
Reexamination Certificate
1999-07-13
2001-10-23
Callo, Laura A. (Department: 3635)
Static structures (e.g., buildings)
Processes
Filling preformed cavity
C052S745130, C052S745200, C052S747120, C052S309120, C052S309170, C052S220200, C052S259000, C052S091200, C052S505000, C052S437000, C052S438000
Reexamination Certificate
active
06305142
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a prefabricated building assembly for low-cost construction of walls, roofs, and floors that includes the use of a plurality of prefabricated building panels having a foam plastic core approximately 4 ft. wide and 24 ft. long and 4 to 8 in. thick, with the end faces and side faces of the building panel having prefabricated semicircular channels that engage preformed foam connectors for joining the panels together to form walls, roofs, and floors. Each panel also includes a poly-concrete coating on its outside to provide a finish, structural strength, prevent buckling, and for weather protection. Each panel also includes a plurality of circular passages or voids that extend all the way through the thickness of the panel across the width of each panel from side to side, each of the passages being parallel and spaced between 2 to 4 ft. a part, which receive poured concrete when the panels are used to form an internal steel reinforced concrete belt in a suspended frame. Each construction panel also includes internal passages, vertically and horizontally, for utility wires.
2. Description of the Background Art
The use of foamed plastic building materials for construction of building walls, roofs, and other structures is known in the art. Attempts have also been made to reduce construction costs by implementing the overall building construction with foamed plastic materials. Building construction using combinations of polyconcrete as the basic building material is also known.
U.S. Pat. No. 4,038,798, issued Aug. 2, 1977 to Sachs, describes a composite permanent block-form for reinforced concrete construction and the method of making the same. Because of the laminate construction of Sachs, Sachs does not offer and insure sufficient structural integrity. Sachs also does not provide for a coated foam structure that uses polyconcrete.
U.S. Pat. No. 4,249,354, issued Feb. 10, 1981 to Wynn, shows a reinforced, insulated wall construction with tube liners for concrete that uses high-compressive and side-loading strengths achieved by central supporting reinforcing members in vertical passageways. Although Wynn does disclose a foamed core, the construction of the block is quite different than that described by the Applicant in Applicant's invention.
U.S. Pat. No. 4,532,745, issued Aug. 6, 1985 to Kinard, describes a channel and foam block wall construction. Concrete is poured into U-shaped channels that are formed in foam plastic blocks. The construction and operability of the blocks shown in Kinard are quite different than that described by the Applicant. Applicant's invention includes a foam core with a thin coating for structural rigidity using a polyconcrete. Voids are also preformed in Applicant's invention which are used to receive utility wires and pipes.
U.S. Pat. No. 4,774,794, issued Oct. 4, 1988 to Grieb, shows an energy efficient building system that provides a foam cement building. The Grieb building blocks include foam covered by cement which include reinforced fiberglass mesh and strands. The Grieb building block is basically a laminate and is quite different than Applicant's construction block.
U.S. Pat. No. 4,924,641, issued May 15, 1990 to Gibbar, Jr., shows a polymer building wall form for construction. The Gibbar construction includes the use of foam urethane having a series of spacers formed therein to provide for a concrete wall to be poured therein.
U.S. Pat. No. 5,488,806, issued Feb. 6, 1996 to Melnick, et al., describes block forms for receiving concrete. The construction basically uses plastic foam blocks that retain liquid concrete.
U.S. Pat. No. 4,194,919, issued Mar. 25, 1980 to Hattori, et al., describes a method for increasing flexural strength of cement compositions. The flexural strength of hydraulic cement compositions are increased by water soluble epoxy resins. There is no description in Hattori to provide a plastic foam core that is coated with the epoxy cement mixture.
U.S. Pat. No. 5,162,060, issued Nov. 10, 1992 to Bredow, et al., provides a polymer modified cement with improved chemical resistance.
U.S. Pat. No. 5,252,636, issued Oct. 12, 1993 to Ellenberger, et al., provides for a dry mixture for epoxy cement concrete. There is no description or discussion in Ellenberger to provide a foam core with a coating of epoxy resin and a cement mixture as described in Applicant's invention herein.
None of the references cited herein disclose Applicant's building block having a foam core with an integral coating of polyconcrete, nor provide a low-cost lightweight construction block that includes preformed voids for the form for steel reinforced concrete with a low-cost permanent coating that prevents lateral buckling and may include voids for utilities.
SUMMARY OF THE INVENTION
A prefabricated building assembly for constructing walls, roofs, and floors, comprising a prefabricated building panel made up of substantially a foam plastic core approximately 24 ft. long, from 6 to 12 in. thick, and of varying width, depending upon the job specifications and requirements.
The building panel includes 4 in. in diameter voids that extend through the thickness of each panel along its width so that when the panel is disposed horizontally each of the voids are vertically disposed to receive poured concrete and rebar. Each of the building panel 4 in. circular voids are spaced 2 to 4 ft. a part.
The end face and side face perimeter around the thickness of the building panel includes a half-round or semicircular groove or channel on all faces. The purpose of these semicircular channels is to provide connection between adjacent panels when joined together, such that a cylindrical circular connector is disposed therein for alignment and connection of adjacent panels.
The building panel includes an epoxy or acrylic resin and portland cement coating approximately ¼ in. thick on its side walls to provide strength and a finished surface to the plastic foam core of the building panel. The connector system, which includes a plurality of cylindrical, elongated members which are also made of foam that has been removed from the construction of the basic foam panel (the 4 in. voids), is also coated with the epoxy or acrylic resin and portland cement coating. The coating is also used as an adhesive along the connectors and wall interface.
The building panel also includes a plurality of small passageways, both horizontally and vertically disposed, for electrical wiring, the passageways being approximately ¾ in. in diameter.
The building assembly may be used to construct walls, roofs, and floors. The building assembly system described herein can also be used to form roof connections and a building roof with supporting trusses.
The building assembly also includes corner posts that are comprised of elongated, square foam pieces that can be 4 to 8 ft. long, having at least two sides that are adjacent to each other, coated with the resin and portland cement coating. The other sides include the semicircular or half-round channels disposed longitudinally, which also receive poured concrete vertically for stabilizing the corner post at the juncture of two walls that are formed at a 90-degree connection.
One of the purposes of the building assembly in the present invention is to take advantage of the use of styrene or urethane foam blocks as the bulk of the construction, and the fact that it can be prefabricated in a factory environment and then shipped to the building site where very little, if any, manual labor cr finishing is required. The building assembly in accordance with the present invention has impact and compressive load strength and uses poured concrete for windloading and to increase the compressive strength. When using the present building assembly, the time of construction is greatly reduced. The building panels and assembly connectors are prefabricated in a factory and come in a finished condition. Labor costs on site for on-site construction is greatly reduc
Brisson Dale J.
Hammond W. Scott
Callo Laura A.
Malin Haley & DiMaggio, P.A.
Recobond, Inc.
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