Static structures (e.g. – buildings) – With synthetic resinous component – Foam
Reexamination Certificate
1999-07-07
2001-02-13
Purol, David M. (Department: 3634)
Static structures (e.g., buildings)
With synthetic resinous component
Foam
Reexamination Certificate
active
06185891
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to insulating foam building materials and methods for their use; particularly to buildings formed from structural composite members composed of rigid foam having a concrete formulation integrally affixed thereto that are hurricane resistant.
BACKGROUND OF THE INVENTION
Standard methods of construction generally require that a building, for example a single-family residential structure, be formed from a plurality of wooden or metal framing members, e.g. beams, joints and trusses; which are erected upon a solid foundation, and through which mechanically required components, e.g. pipes, electrical wiring, telephone cables and heat and air conditioning ducts and/or conduits are routed. After the mechanicals are contained within the framing members, the outer sheathing is attached thereto, forming the exterior wall and roof surfaces. Insulation is then fitted about the various interstices of the framed areas, and an interior wall surface, e.g. gypsum board, paneling, plywood sheathing, plaster or the like, is applied to form the interior walls and ceilings. Application of decorative and weather protective materials, e.g. brick, aluminum siding, shingles or the like is subsequently applied to the exterior surfaces, along with paint and moldings to complete the construction and render it aesthetically pleasing. Such methods of construction are time consuming and require the use of numerous crews of highly skilled tradesmen to complete each segment of the project. In order to render such construction more economical, and to allow a home to be completed in a shorter time frame, various alternative construction methods have been developed. For example, so-called modular homes have been constructed which use pre-fabricated sections, e.g. roof trusses, walls, and sometimes entire rooms, which sections are interconnected on-sight so as to form the finished structure. Such structures require numerous modifications in order to make them storm or hurricane resistant.
DESCRIPTION OF THE PRIOR ART
U.S. Pat. No. 5,771,649 describes a technique for forming a structure using foam blocks which are sprayed with a concrete formulation, which can include both a polymer and a fibrous material, and which is sprayed to form a concrete monocoque shell house.
U.S. Pat. No. 4,774,794 describes an energy efficient building system containing foam structural blocks having a reinforcing grid of fiberglass which is coated with a fiberglass reinforced cementitious acrylic polymer mixture. The mixture bonds to the fiberglass reinforcing grid, on the exterior and interior as necessary, to provide adequate strength. Junctions between blocks are held together by a continuous spline joint.
French Patent No. 767,681 illustrates building blocks which are stacked and secured via rods placed through judiciously spaced holes therethrough.
U.S. Pat. No. 3,292,331 describes an interlocking block wall construction wherein passages in stacked blocks are aligned so as to form a continuous vertical channel. The vertical channel allows for the positioning of reinforcing rods in said channels and cement composition about the rods.
U.S. Pat. No. 3,782,049 describes a plurality of wall forming blocks made from a foamed plastic material having various channels therethrough which are vertically aligned during assembly. A concrete slurry poured into these openings forms a concrete supporting grid within the wall.
U.S. Pat. No. 5,123,222 describes hollow foamed plastic forms for poured concrete.
U.S. Pat. No. 2,269,018 described glazed building blocks having spaces therein which may be filled with insulating material.
U.S. Pat. No. 5,566,521 discloses a concrete form mold unit constructed from a lightweight insulative material. Concrete and reinforcing rods fill rows of vertical core spaces thereby defining post structures. Surface finish materials are later joined to the attaching plates.
U.S. Pat. No. 5,231,813 describes insulated panels formed from a high density polymeric foam body defined by an interior wall spaced from an exterior wall wherein the exterior wall contains a cementitious layer coextensive therewith and wherein various interstices are filled with reinforcing rods and cement compositions.
U.S. Pat. No. 3,755,982 describes building panels wherein facing panels are sandwiched about a foam core. Vertical reinforcing rods are positioned to align the panels with the foundation and the injection of concrete formulations about the reinforcing rods strengthens and solidifies the structure.
U.S. Pat. No. 4,641,468 describes building panel structures and methods for erecting buildings utilizing structural foam combined with rigid framing members to provide a low cost modular building design.
All of these prior art attempts suffer from various shortcomings. The method of attachment of the variously disclosed panels require the use of differing types of hardware and the construction of passages or keyways in the panels. This creates a more complicated and costly structure, adds hardware requirements and concentrates any shearing forces at the particular points of attachment. Furthermore, the prior art also fails to disclose a composite concrete formulation which forms a self adherent concrete coating layer that is integrally bonded to the underlying foam upon curing. Lastly, none of the prior art methods describe a system whereby the roof assembly is formed contiguous with the sidewalls of the structure, resulting in a dwelling having a monolithic structure which is capable of resisting winds in the range of 155-310 mph without damage.
Thus, there exists a need in the construction industry for an economical building material and method for its use which results in easily assembled structures having enhanced thermal efficiency and increased resistance to wind damage.
SUMMARY OF THE INVENTION
The present invention is directed toward a new method of building construction which eliminates the traditional framed wall and trussed roof construction and provides a low cost housing construction that is storm and hurricane resistant. Rigid blocks of environmentally sensitive foamed styrene are utilized as the underlying structure of both the wall and roof members. Starting with a rigid base, e.g. a monolithic concrete slab, reinforced concrete slab, or the like, support panels of rigid foam are fastened thereto by using an adhesive material, such as a urethane, at the foam/concrete interface along the points of intersection. The foam is specially modified by creating channels suitable for accepting steel reinforcing rods spaced on four foot centers and about which is poured a concrete slurry having a composite strength of about 3000 psi. The channels act as a form for producing post, belt and suspender beams which are in turn tied to the foundation or slab, the exterior wall perimeter, the roof panels and peak. Upon setting, the concrete slurry/reinforcing rod combination thus creates a rigid skeletal structure about which the foam panels are anchored. In a similar manner, the panels which are to form the roof members, are arranged so that vertically extended sections of the wall section reinforcing rods are adjusted to be retained in the roof member reinforcing channels, and about which is poured a polymer-concrete slurry having a composite strength of about 6000 psi. Additionally, a centrally located reinforcing member constructed and arranged so as to support the expected roof loads, e.g. a specially configured steel reinforcing beam, such as a W-section, I-beam configuration, or equivalents, having perforations set upon four foot centers, accepts the reinforcing rods of the intersecting roof members.
Upon injection and solidification of the concrete reinforcing slurry throughout the passages created in the foam a specially formulated cementitious layer is applied to the interior and exterior faces of the styrene foam panels. The aqueous cement slurry includes an effective amount of ethylene vinyl acetate (EVAC). A plurality of fine polymer fibers is further added, and the mixture is blended
McHale & Slavin
Purol David M.
R-40 Homes, Inc.
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