Note: Descriptions are shown in the official language in which they were submitted.
CA 02568610 2006-11-21
FOAM CORE PANEL FOR PREFABRICATED BUILDINGS
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 modules made of
panels having a foam plastic core of the desired thickness, with the side
edges of the building
panel having prefabricated semicircular channels that engage tubular
connectors for joining the
panels together to form walls, roofs, and floors. Each panel also includes a
polymer coating,
corrugated plastic or wood sheeting on its outsides to provide a finish,
structural strength, and
rigidity. Each panel also includes a plurality of circular bores 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 at a predetermined and equal distance apart
to accommodate
partially threaded steel rods or cables which fasten the modules together to
provide rigidity for
the structure.
The modules may be used to construct walls of various sizes provided that the
diameter of the
tubular members or pipes vary accordingly. Tubular flange type connectors are
inserted at the
bottom of each pipe to secure the wall units to the floor by fastening means
such as screws. The
pipes may be made of plastic or metal.
Plywood or cement floors or foundations are also possible with system. The
building system
may be used vertically for traditional or arch-type buildings and for dome-
type structures. The
exterior of the modules is preferably covered with a waterproof fabric such
vinyl.
Background of the Invention
U.S. Pat. No. 4,194,919 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.
CA 02568610 2006-11-21
U.S. Pat. No. 5,921,046 to Hammond, et al., provides a plastic foam core for
epoxy cement
concrete. There is no description or discussion to provide a foam core with a
coating of epoxy
resin and plastic pipe 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 vertical plastic pipes nor provide a low-cost lightweight
construction block that
includes preformed voids for horizontal steel rods and a low-cost permanent
coating that
prevents lateral buckling.
Summar,y 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..
Each of the building
panels has horizontal spaced circular voids to receive threaded steel rods or
cables .
The side face of the building panel includes a half-round or semicircular
groove or channel 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 coating, corrugated
plastic board or
plywood on its side walls to provide strength and a finished surface on the
plastic foam core of
the building panel. The connector system, which includes a plurality of
cylindrical, elongated
members, which are also made of plastic and may be filled with foam. The basic
foam panel is
also coated with the epoxy or acrylic resin. The coating is also used as
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 3/4 in. in
diameter.
2
CA 02568610 2006-11-21
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.
One of the purposes of the building assembly in the present invention is the
use of styrene or
urethane foam blocks for the construction, that it can be prefabricated in a
factory environment
and then shipped to the building site, so that less manual labor or finishing
is required. The
building assembly in accordance with the present invention has impact and
compressive load
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.
After the footer and slab have been poured, a building panel in accordance
with the present
invention will be placed on top of tubular flange connectors that are secured
to the slab by
screws. A roof type second building panel will be mounted on top of the first
building panel and
will include cylindrical connectors. Again, the epoxy or acrylic resin coating
can be used for
adhering the cylindrical connectors to the recessed walls of each of the
building blocks, apart in
the building panels, with the tubes progressing vertically up to the top of
the wall. The same
construction technique can be used on roofs, as described in greater detail
below.
The present invention seeks to provide a building panel for forming walls,
roofs and floors in a
building constructed with a tubular frame including an expanded foam, plastic
core substantially
rectangular in shape, first and second faces defined by the ends of said core,
the end faces each
having a concave, semicircular recessed channel, said core also including a
plurality of circular
voids extending through the thickness of said core between said first and
second face, each of
said plurality of said circular voids being essentially parallel and each of
said circular voids
being spaced apart to receive tension members, a plastic resin forming a
coating, integrally
applied to at least said first face, said coating being approximately one
quarter inch thick for
added rigidity; and the tubular frame comprising cylindrical, elongated
members, sized in
radius to fit snugly within said semicircular recessed channels in the core
faces, said connector
being formed of a plastic pipe for joining a pair of said building panels
together.
3
CA 02568610 2006-11-21
The present invention also seeks to provide a panel, wherein the building
panel foam expanded
plastic core is made of styrene or acrylic the building panel plastic foam
core is made of urethane
and wherein the plastic pipe of the tubular frame is filled with plastic foam.
Brief Description of the Drawings
FIG. 1 is a perspective view of wall and roof panels in accordance with this
invention
FIG. 2 is a perspective view of side by side panels
FIG. 3 is a perspective view of an assembled building structure
FIG. 4 is a perspective view of a dome shaped building structure, and
FIG. 5 is a perspective view of the pipe arrangement of the structure of FIG.
3.
Description of the Preferred Embodiment
The building assembly in accordance with the present invention uses
prefabricated modules.
These modules or panels 10 comprise rigid foam plastic that has wood sheeting
11 provided
with adhesive on both interior and exterior sides of panels to ensure its
rigidity as shown in FIG.
1-5. Both vertical sides of panels have a semicircular concave recessed
vertical channel 14, to
receive a plastic pipe 16 of the same diameter provided with adhesive as shown
in FIG. 1- 2.
Each building panel is provided with horizontal holes or voids (5/16 in.) 20,
in order to insert
partially threaded, 24 in. long, reinforcing steel rods 12 spaced every 2 ft.,
as shown in FIG. 1-2
and 4-5. A washer 26 and bolt connector 28 is placed on reinforcing steel rods
12 outside of
vertical plastic pipe 16 as shown in FIG. 2 and 4. The steel connector 28 is
used to join the
horizontal reinforcing steel rods 12 after each panel is in place to secure
the panels 10 together in
order to form one unit as shown in FIG. 2, 4 and 5. Plastic or metal angled
connectors 30, 30a
with set screws 38 are used, to join side wall panels to roof panels as shown
in FIG. 3- 4. In
addition, the wall panels have a pre-determined angle at the top 15, where as
the roof panels have
a pre-determined angle at the top 15a and bottom 15b, in order for both panels
(wall and roof or
both roof panels) to join perfectly to create a 45 degree angle, as shown in
FIG. 1. A metal
anchor connector 30b is used, with set screw 38, at bottom of each pipe 16 on
either side of
panels to secure them to the foundation with 3 or 41ag screws 36 at predrilled
holes on steel
4
CA 02568610 2006-11-21
plate of connector, whether it is wood or concrete as shown in FIG. 2-5. The
building unit is
covered with a waterproof, fire retardant and U.V. protected vinyl membrane 22
which has a
horizontal loop 32 placed at the bottom of each side, to insert a horizontal
plastic or metal pipe
34, as shown in FIG. 4-5. It is fastened with lag screws 36 spaced every foot
of the foundation
or floor, whether it is concrete or wood as shown in FIG. 2-5. Specifications
above, also apply to
arch- type dome or semi-circular structures as shown in FIG. 5. It is very
important that all
dimensions of materials are subject to change depending on the size of
building required.
