Static structures (e.g. – buildings) – Composite prefabricated panel including adjunctive means – Sandwich or hollow with sheet-like facing members
Reexamination Certificate
2000-07-07
2001-12-04
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Composite prefabricated panel including adjunctive means
Sandwich or hollow with sheet-like facing members
C052S309120, C052S742140, C052S272000
Reexamination Certificate
active
06324812
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to concrete construction and form systems for concrete construction. More particularly, it concerns a monolithic paraseismic concrete construction.
BACKGROUND
The use of concrete forms for the moulding of a concrete wall is well known in the art and widely practised. Conventional concrete forms are made by securing either panelling such as plywood or individual boards to reinforcing studs. The individual forms are placed in the desired position and after the concrete is set, the forms are removed. The use of these forms is expensive, since reuse of the lumber is limited and a substantial amount of labour is required to build the forms.
One of the considerations involved in the pouring of concrete walls is the strength of the wall which is required for the building. Thus, the tensile strength and compressive strength are properties which must be taken into consideration in designing the concrete wall. Factors which are involved in determining the final properties include the type of concrete mix and the thickness of the wall. Naturally, one can increase some of the strength properties by pouring thicker walls; this will however increase the cost. Naturally, it is desirable to use as little concrete as possible to achieve the required properties.
Prior patent application no WO97/43507 in the name of the applicant discloses a concrete wall with an overall corrugated configuration. This wall, which requires a lot less concrete mixture to make than a conventional planar concrete wall, shows much better final properties than the latter.
Other examples of concrete walls of different shapes known in the prior art are given in the following patent documents: U.S. Pat. Nos. 1,373,523; 2,272,659; 2,523,713; 3,664,630; 5,491,947; FR 2,161,407; SW 75,941; IT 420,596.
Although, some of these above-mentioned prior art documents may disclose concrete walls having relatively good properties, none of those documents discloses or suggests a whole construction that would have excellent paraseismic properties, neither a simple and inexpensive way to build such paraseismic construction.
Also, many difficulties are encountered in the making of high-performance, paraseismic ecological structures. Among those, there are the following: the unevenness and geological quality of the soil, the flooding, and thawing and freezing cycles are factors which increase the construction costs and accelerate the degradation of the buildings; the poor quality of the cement; the high cost of steel framework; the lack of qualified workers in certain countries; the necessity of reducing sophisticated tools such as mechanical crane; the lack of substructure and of means of transport; the lack of electrical energy in certain regions; problems related to transportation of prefabricated elements or houses; and the necessity of using materials other than wood which could be very costly and which generally has a poor resistance to termites, mushrooms, humidity, fire and earthquakes.
There is thus presently for a wind proof paraseismic technology, and a necessity of developing a global technology using the same material other than wood for the floor, the walls and the ceiling of a construction.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a concrete construction that will satisfy this need and will overcome many of these above-mentioned difficulties.
It is a further object of the present invention to provide a concrete form system which is easy to assemble and use.
It is also an object of the present invention to provide a method for forming a concrete construction wherein the use of concrete is minimized.
In accordance with the present invention, some of these objects are achieved with a concrete construction comprising:
a bottom wall;
a plurality of sidewalls extending upright from the bottom wall, each sidewall being made of concrete and having a generally overall corrugated cross section with alternating recesses and ridges extending in a substantially vertical direction; and
a top wall intersecting the sidewalls at upper edges thereof, the top wall being made of concrete and having a top face generally parallel to an under face, the under face having a generally corrugated relief with alternating recesses and ridges extending in a substantially horizontal direction.
Preferably, the bottom wall is made of concrete with a top face generally parallel to an under face, the under face having a generally corrugated relief with alternating recesses and ridges extending in a substantially horizontal direction.
The present invention also proposes a kit of modular foam panels used to make a construction as described hereinabove. The kit comprises:
a) a plurality of corrugated foam panels having a generally rectangular shape outlined by a first pair of opposite corrugated side edges and a second pair of opposite linear side edges and a generally corrugated relief with alternating recesses and ridges extending in a longitudinal direction between the two corrugated side edges, said recesses and ridges having a semi hexagonal shape with two tapering segments and a third segment interconnecting a thinner end of the two tapering segments;
b) at least two comer foam panels of a first type each including:
a linear first edge opposite a corrugated second edge with alternating recesses and ridges matching the corrugated side edges of the corrugated foam panels, the linear first edge and the corrugated second edge extending in substantially parallel planes, said recesses and ridges having a semi hexagonal shape with two tapering segments and a third segment interconnecting a thinner end of the two tapering segments;
substantially planar wall sections extending perpendicularly to the parallel planes of the first and second edges between the ridges of the second edge and segments of the first edge; and
polyhedron wall sections extending between the recesses of the second edge and segments of the first edge; and
c) at least two comer foam panels of a second type each including:
a corrugated first edge matching with the corrugated side edges of the corrugated foam panel and having alternating recesses and ridges extending in a first plane, the recesses having a semi hexagonal shape with two tapering segments and a third segment interconnecting a thinner end of said two tapering segments;
a corrugated second edge having alternating recesses and ridges matching with the corrugated side edges of the corrugated foam panel and extending in a second plane substantially perpendicular to the first plane, the recesses having a semi hexagonal shape defined by two tapering segments and a third segment interconnecting a thinner end of said two tapering segments;
substantially planar wall sections extending in the first plane between the ridges of the first and second edge; and
polyhedron wall sections extending between the recesses of the first and second edge.
In a further aspect of the present invention, there is provided a method of making a concrete construction as described hereinabove, comprising the steps of:
a) providing a kit of foam panels as defined above;
b) preparing concrete beams that will be used later on to construct a top wall of the construction, comprising setting one of the corrugated foam panels on a planar surface with the longitudinal direction extending parallel to the planar surface and pouring a concrete slurry only in the recesses of said corrugated foam panel so to form a plurality of parallel concrete beams;
c) erecting the sidewalls of the construction comprising the steps of:
setting, wall forms for forming the sidewalls of the construction, each of the wall forms comprising a pair of the corrugated foam panels with their longitudinal direction set to extend in a substantially vertical direction, the pair of panels defining a cavity therebetween with a corrugated configuration, one of the corrugated foam panels being designated as an outside foam panel and the other one being designated as an inside foam panel, the wall forms being
3417191 Canada Inc.
Darby & Darby
Friedman Carl D.
Slack Naoko
LandOfFree
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