Note: Descriptions are shown in the official language in which they were submitted.
CA 02353234 2001-07-18
Variable Size Panels for Construction Blocks and
Building System Therewith
Field of the Invention
The present invention relates to building panel
components for the manufacture of variable design
building blocks and to the method of use of such
components for the manufacture of building structures.
Background of the Invention
Recent developments in residential, commercial,
multi-unit and institutional building construction have
included the use of rigid polymer components and forms
to provide the form-work for the load bearing or
non-load bearing walls. Typically, the material used in
the form-work is concrete with the form-works remaining
in place thereafter. In such modes of constructions, it
may be required to finish the exterior and interior
surfaces of the walls for the purpose of weather
proofing and aesthetic design appearance. As a further
disadvantage, there is the cost associated with concrete
materials and the risk of damage to load bearing and
non-load bearing walls made of this material associated
with seismic activity. More traditional, wood frame
type of construction, although generally economical, has
certain disadvantages associated with it. Use of
pressure treated wood is associated with the risk of
harmful vapours. Additionally, use of this traditional
building material is associated with risks with respect
to termite and fire hazards. Waterproofing and
insulation is also required to make such structures
habitable to humans or satisfactory for the intended
purpose.
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Accordingly, there is a need for structural components
which are easy to manufacture and transport and to
assemble into an edifice, which will provide for a
building without the above-referenced disadvantages.
Summary of the Invention
The present invention in one aspect provides for a
building panel of polymer or other durable material and
capable of being of a variable size, comprising of means
for engaging adjacent panels, a brace track means for
positioning and holding a first row of said building
panels which, with end panels, form a block or row of
blocks of a width substantially the same as the width of
the brace track, comprising an interior wall face and an
exterior wall face, defining a block cavity, brace means
positioned at regular intervals within the formed cavity
of the blocks and slots located at regular intervals on
the interior face sides of the building panels, within
the cavity of the formed blocks for engagement of the
braces.
In another aspect, the present invention provides for a
block or wall formed as aforesaid into which is
deposited polyurethane material.
In another aspect, the present invention provides for a
method of manufacturing an edifice comprising the use of
the building panels as aforesaid.
Other features and advantages of the present invention
will become apparent from the following detailed
description. It should be understood, however, that the
detailed description and the specific examples while
indicating preferred embodiments of the invention are
given by way of illustration only, since various changes
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and modifications within the spirit and scope of the
invention will become apparent to the skilled person in
the art from this description.
Brief Description of the Drawings
The invention will now be described in relational to the
drawings in which:
Figure 1 is a side elevation of a building panel with
1/4 inch bevel, 16 inch height and 36 inch length.
Figure 2 is a top view of a building block formed of the
building panels of the present invention with
structural braces positioned at 12 inch intervals.
Detailed Description of the Invention
The building panel of the present invention may be
manufactured of any suitable durable material such as
polyethylene. The exterior surface of these building
panels may be of any colour or texture design as may be
intended for the desired purpose. For example, for
exterior wall purposes, the texture may be of stucco or
of any resilient and durable exterior kind.
For formation of a wall, a first block is formed on the
brace track means which have been previously laid in any
desired pattern to form the layout of the edifice to be
raised. At an appropriate corner, a first or starter
block is prepared by the placing of a first panel which
is of tongue and groove construction. The brace track
means will be of a desired width for the formation of a
block. For example, this may be of a 12 inch width for
the formation of a wall of such thickness. For enhanced
rigidity and bracing, the typical first block will be of
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a length identical to the width of the brace track
means, to thereby provide for overlapping interlocking
securing as levels of blocks are superimposed in
formation of a wall. Adjacent building panels are
engaged by tongue and groove means along the bracing
track to form a first block level of a wall in
construction. The interiors of the building panels
comprise of slots into which at regular intervals, such
as 12 inches, are inserted for the first level of blocks
half-brace means, for the purpose of providing rigid
bracing. The said brace means may be arcuate or
channel-like in construction to provide means for the
support of reinforcement or bracing bars as well as to
provide for a conduit for the passage of electrical
wiring, fibre cables, plumbing and the like. End cap
means are also added, by again tongue and groove
engagement, with the building panels at the end of a
bracing track for enclosure and formation of the block
row. The half-brace means engaged with the first block
row are approximately half the height of the building
panels.
On completion of a first row of blocks, one or more
subsequent layers of panels may be engaged in the manner
as above described for the creation of a wall of desired
height. Full brace means are inserted in the slots for
engagement at regular intervals. The brace means are of
a sufficient height, typically the same height as a
building panel, such as to brace for support two panels,
one on top of the other.
During the construction of a building, at regular
intervals any suitable polymer foam material, for
example polyurethane may be blown into the block spaces,
to fill the spaces therein and to provide a rigid wall
structure.
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Such a rigid wall structure will be of extremely high
strength and durability with excellent acoustic and
thermal insulation properties. This will nevertheless
be of easy means of construction and inexpensive
relative to the use of other materials and other means
of construction.
At corners, overlapping first blocks or starter blocks
will be engaged in overlapping contact as described
1.0 above to assist in wall rigidity. For the construction
of a corner using first starter blocks, a panel face
will be included across the width of the brace track
means, which panel will include an opening generally
parallel to the brace means, to provide for a conduit
for plumbing, electrical, wires, cables, reinforcement
bars and the like.
For the placement of doors, windows, other openings and
the like, frames of PVC extruded material may be
positioned at the desired locations where blocks have
been formed of the desired dimensions from pre-placed
panels of the present invention. Construction of the
wall by adding the desired levels of building panels to
form rows of blocks may be continued, to the required
height around and above the frames positioned for doors
and windows. Any usual means known to the skilled person
may then be utilized for positioning and engaging doors
and windows of conventional manufacture, which would be
readily available for the purpose of such construction.
Both interior and exterior panels may be of 1 inch or
1/4 inch construction or of any other dimension in
thickness as may be desired. Interior or exterior walls
may be covered in stucco, wood, brick or any other
desired finish. This may be pre-applied to the panels
prior to assembly for wall construction.
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The bracing track means, may be of any suitable durable
material such as non-corrosive metals or polymer and may
be laid down in any suitable pattern desired by the
builder, including a T-form for the preparation of
internal walls or at an L-angle.
Upon completion of the construction of a wall, the top
row of blocks may be capped and suitable roofing material
applied for enclosure of the structure.
While the present invention has been described with
reference to what are presently considered to be the
preferred examples, it is to be understood that the
invention is not limited to the disclosed example above.
The invention is intended to cover various modifications
and equivalent arrangements included within the spirit
and scope of appended claims.
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