Note: Descriptions are shown in the official language in which they were submitted.
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COMPOSITE PRE-FORMED CONSTRUCTION ARTICLES
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to pre-formed
building and construction panels that include one or more
reinforcing structural elements embedded in a foamed
thermoplastic matrix as well as insulated concrete forms
with internal blocking and bracing elements.
2. Description of the Prior Art
It is known to use construction elements made of
expanded plastics, for example expanded polystyrene, in
forms of boards or section members of suitable shape and
size. These members provide thermal and sound insulation
functions and have long been accepted by the building
industry.
It is also known that, in order to confer adequate
self-supporting properties to such construction elements,
one or more reinforcing section bars of a suitable shape
must be incorporated into the mass of expanded plastics.
U.S. Patent Nos. 5,787,665 and 5,822,940 discloses a
molded composite wall panels for building construction
that includes a regular tetragonal body of polymer foam
and at least one light metal gauge hollow stud in the
body. The edges of the studs are even with a surface of
the polymer foam so drywall can be attached thereto.
U.S. Patent 6,098,367 discloses a constructive
system applied to buildings to form walls by means of
modular foldable frames that allow for the placement of
blocks or plates. The frames with the resistant channels,
rods, blocks or plates, resist better strong winds and
seismic movements.
U.S. Patent No. 6,167,624 discloses a method for
producing a polymeric foamed material panel including the
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steps of providing a polymeric foamed material, cutting
the polymeric foamed material until reaching a
preconfiguration cut point, cutting subsequently from the
preconfiguration cut point a brace-receiving
configuration in the polymeric foamed material, and
sliding a brace member into the brace-receiving
configuration to produce a polymeric foamed material
panel.
U.S. Patent No. 6,235,367 discloses a molded
construction product, having one or more walls and an
inner core section, including a composition matrix having
a resin system, a catalytic agent, and filler compounds
for forming the walls; a foam core system for forming the
inner core section, a curing agent and a drying agent. A
structural reinforcement support system is provided for
reinforcing the structural integrity of the composition.
A locking system is provided for joining one or more of
the molded products.
EP 0 459 924 discloses a self-supporting
construction element made of expanded plastics material,
specifically a floor element, which includes a
substantially parallelepipedic central body in which a
reinforcing section bar, made of a thin metal sheet
shaped as an I-beam, is integrated during the molding
step.
U.S. Patent No. 5,333,429 discloses a composite
panel with a structural load-bearing wooden framework
formed by a substantially parallelepiped body of expanded
synthetic material. The panels have a plurality of
longitudinal channels extending for the whole height of
the panel. A series of channels uniformly spaced and
staggered are open on the adjacent face of the panel and
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have a T-shaped cross section. In these open channels fit
T-shaped cross section wooden posts, the stem portion of
which emerges out of the open channels and project from
the surface of the panel.
WO 2002/035020 discloses a composite construction
element that includes a body made of expanded plastics
material and a slab-shaped coating element associated to
the body. The slab-shaped coating element includes a
plurality of substantially adjoining and substantially 13-
shaped adjacent sections provided with respective means
for mechanically clinching the slab-shaped element to the
expanded plastics material.
While the construction elements described above have
on the one hand a light weight, a comparative ease of
installation and a low cost, on the other hand their
application in the art and flexibility of use have been
restrained heretofore by their poor fire-resisting
properties and/or the propensity for mold to grow on
finished surfaces attached thereto.
This inadequate resistance to fire is essentially
related to the fact that construction elements made of
expanded plastics show an insufficient capability to
securely hold outer covering layers, such as the plaster
layers used for the outer surface finish or contain the
expanded polymer body, in flammable molten or liquid
form, that occurs from the heat generated from a fire.
When exposed to fire, in fact, the expanded plastics
soon shrink into a shapeless mass of reduced volume,
which can flow and burn, and in some cases with the
ensuing separation of the outer covering layers and rapid
collapse of the whole structure.
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In addition, an undesirable separation of the outer
covering layers may be caused in some instances by a
premature "aging" of the plastics surface to which these
coverings adhere, a separation which may be further
fostered by exposure to heat sources, dusts, fumes,
vapors, or chemical substances coming from a source close
to the construction elements.
U.S. Patent 6,298,622 and WO 2004/101905 disclose an
approach to overcoming the above-described problem by
using a self-supporting construction element of expanded
plastics for use as floor elements and walls of
buildings. The construction elements include a central
body, substantially parallelepipedic in shape and having
two opposite faces; at least one reinforcing section bar
transversally extending across the central body between
the faces thereof and embedded in the expanded plastics;
a lath for supporting at least one layer of a suitable
covering material, associated to a fin of the reinforcing
section bar lying flush with and substantially parallel
to at least one of the faces of the construction element.
However, moisture buildup between the lath and
construction element can lead to mold and mildew growth
and the ability to easily run electrical lines without
cutting into the construction elements have limited the
desirability of this approach.
Concrete walls in building construction are most
often produced by first setting up two parallel form
walls and pouring concrete into the space between the
=
forms. After the concrete hardens, the builder then
removes the forms, leaving the cured concrete wall.
This prior art technique has drawbacks. Formation of
the concrete walls is inefficient because of the time
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required to erect the forms, wait until the concrete
cures, and take down the forms. This prior art technique,
therefore, is an expensive, labor-intensive process.
Accordingly, techniques have developed for forming
modular concrete walls, which use a foam insulating.
material. The modular form walls are set up parallel to
each other and connecting components hold the two form
walls in place relative to each other while concrete is
poured there between. The form walls, however, remain in
place after the concrete cures. That is, the form walls,
which are constructed of foam insulating material, are a
permanent part of the building after the concrete cures.
The concrete walls made using this technique can be
stacked on top of each other many stories high to form
all of a building's walls. In addition to the efficiency
gained by retaining the form walls as part of the
permanent structure, the materials of the form walls
often provide adequate insulation for the building.
Although the prior art includes many proposed
variations to achieve improvements with this technique,
drawbacks still exist for each design. The connecting
components used in the prior art to hold the walls are
constructed of (1) plastic foam, (2) high density
plastic, or (3) a metal bridge, which is a non-structural
support, i.e., once the concrete cures, the connecting
components serve no function. Even so, these members
provide thermal and sound insulation functions and have
long been accepted by the building industry.
Thus, current insulated concrete form technology
requires the use of small molded foam blocks normally 12
to 24 inches in height with a standard length of four
feet. The large amount of horizontal and vertical joints
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that require bracing to correctly position the blocks
during a concrete pour, restricts their use to shorter
wall lengths and lower wall heights. Wall penetrations
such as windows and doors require skillfully prepared and
engineered forming to withstand the pressures exerted
upon them during concrete placement. Plaster finishing
crews have difficulty hanging drywall on such systems due
to the problem of locating molded in furring strips. The
metal or plastic furring strips in current designs are
non-continuous in nature and are normally embedded within
the foam faces. The characteristics present in current
block forming systems require skilled labor, long lay-out
times, engineered blocking and shoring and non-
traditional finishing skills. This results in a more
expensive wall that is not suitable for larger wall
construction applications. The highly skilled labor force
that is required to place, block, shore and apply
finishes in a block system seriously restricts the use of
such systems when compared to traditional concrete
construction techniques.
One approach to solving the problem of straight and
true walls on larger layouts has been to design larger
blocks. Current existing manufacturing technology has
limited this increase to 24 inches in height and eight
feet in length. Other systems create hot wire cut
opposing foamed plastic panels mechanically linked
together in a secondary operation utilizing metal or
plastic connectors. These panels are normally 48 inches
in width and 8 feet in height and do not contain
continuous furring strips.
However, none of the approaches described above
adequately address the problems of form blowout at higher
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wall heights due to pressure exerted by the poured
concrete, fast and easy construction with an unskilled
labor force, and ease of finishing the walls with readily
ascertainable attachment points.
Thus there is a need in the art for composite pre-
formed building panels and insulated concrete forms with
internal blocking and bracing elements that overcome the
above-described problems.
SUMMARY OF THE INVENTION
The present invention provides a composite building
panel that includes:
a central body, substantially parallelepipedic
in shape, that contains an expanded polymer matrix,
having opposite faces, a top surface, and an
opposing bottom surface;
at least one embedded framing stud
longitudinally extending across the central body
between the opposite faces, having a first end
embedded in the expanded polymer matrix, a second
end extending away from the bottom surface of the
central body, and one or more expansion holes
located in the embedded studs between the first end
of the embedded studs and the bottom surface of the
central body, where, the central body contains a
polymer matrix that expands through the expansion
holes; and
a concrete layer covering at least a portion of
the top surface and/or bottom surface.
The present invention also provides a composite
floor panel that includes:
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a central body, substantially parallelepipedic
in shape, containing an expanded polymer matrix,
having opposite faces, a top surface, and an
opposing bottom surface; and
one or more embedded floor joists
longitudinally extending across the central body
between the opposite faces, having a first end
embedded in the expanded polymer matrix having a
first transverse member extending from the first end
generally contacting or extending above the top
surface, a second end extending away from the bottom
surface of the central body having a second
transverse member extending from the second end, and
one or more expansion holes located in the embedded
studs between the first end of the embedded studs
and the bottom surface of the central body;
where, the central body contains a polymer
matrix that expands through the expansion holes;
where the space defined by the bottom surface
of the central body and the second ends of the
embedded joists is adapted for accommodating utility
lines; and
where the composite floor panel is positioned
generally perpendicular to a structural wall and/or
foundation.
The present invention further provides an insulated
concrete form that includes:
a first body, substantially parallelepipedic in
shape, that includes an expanded polymer matrix, having
opposite faces, a first surface, and an opposing second
surface;
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a second body, substantially parallelepipedic in
shape, that includes an expanded polymer matrix, having
opposite faces, a first surface, an opposing second
surface; and
one or more embedded studs longitudinally extending
across the first body and the second body between the
first surfaces of each body, having a first end embedded
in the expanded polymer matrix of the first body, and a
second end embedded in the expanded polymer matrix of the
second body, one or more expansion holes located in the
portion of the embedded studs embedded in the first body
and the second body;
where, the first body and the second body contain a
polymer matrix that expands through the expansion holes;
and the space defined between the first surfaces of the
first body and the second body is capable of accepting
concrete poured therein.
The present invention additionally provides an
insulated concrete form system that includes a plurality
of the above described insulated concrete forms where at
least one of an outer lip or an inner lip of each
insulated concrete form forms a joint with another
insulated concrete form.
The present invention is further directed to
buildings that contain one or more of the above-described
insulated building panels, floor panels, insulated
concrete forms and insulated concrete form systems.
The present invention is additionally directed to a
method of constructing a building that includes:
assembling the composite building panels
described above on a generally flat surface, and
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lifting a first end of the composite building
panel while a second end remains stationary
resulting in orienting the building panel to form a
wall of the building.
The present invention is also directed to a building
constructed according to the above-described method.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-sectional view of a pre-formed
building panel according to the invention;
FIG. 2 shows a side elevation view of a pre-formed
building panel according to the invention;
FIG. 3 shows a perspective view of a construction
method according to the invention;
FIG. 4 shows a partial perspective view of a level
track according to the invention;
FIG. 5 shows a rear elevation view of a wall system
according to the invention;
FIG. 6 shows a front perspective view of a wall
system according to the invention;
FIG. 7 shows a rear side perspective view of a wall
system according to the invention;
FIG. 8 shows an expanded perspective view of a
portion of the wall system of FIG. 7;
FIG. 9 shows a perspective view of a wall system
according to the invention;
FIG. 10 shows a partial top perspective view of a
molding attached to a pre-formed building panel according
to the invention;
FIG. 11 shows a cross-sectional view of the molding
in FIG. 10;
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FIG. 12 shows a cross-sectional view of a pre-formed
building panel according to the invention;
FIG. 13 shows a perspective view of a floor system
according to the invention; and
FIG. 14 shows a perspective view of a floor system
according to the invention;
FIG. 15 shows a cross-sectional view of a pre-formed
building panel according to the invention;
FIG. 16 shows a cross-sectional view of a pre-formed
building panel according to the invention;
FIG. 17 shows a cross-sectional view of a concrete
composite pre-formed building panel system according to
the invention;
FIG. 18 shows a cross-sectional view of a pre-formed
building panel according to the invention;
FIG. 19 shows a perspective view of a metal stud
used in the invention;
FIG. 20 shows a cross-sectional view of a concrete
composite pre-formed building panel system according to
the invention;
FIG. 21 shows a cross-sectional view of a concrete
composite pre-formed building panel system according to
the invention;
FIG. 22 shows a cross-sectional view of a pre-formed
building panel according to the invention;
FIG. 23 shows a perspective view of a metal stud
used in the invention;
FIG. 24 shows a cross-sectional view of a concrete
composite pre-formed building panel system according to
the invention;
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FIG. 25 shows a cross-sectional view of a concrete
composite pre-formed building panel system according to
the invention;
FIGS. 26, 27, and 28 show a cross-sectional view of
metal studs that can be used in the pre-formed building
panels according to the invention;
FIG. 29 shows a partial elevation view of a pre-
formed building panel according to the invention;
FIG. 30 shows a top plan view of a pre-formed
insulated concrete form according to the invention;
FIG. 31 shows a top plan view of a pre-formed
insulated concrete form according to the invention;
FIG. 32 shows a cross-sectional view of a pre-formed
insulated concrete form according to the invention;
FIG. 33 shows a partial perspective view of an
embedded stud used in the invention;
FIG. 34 shows a perspective view of a pre-formed
insulated concrete form according to the invention;
FIG. 35 shows a perspective view of the concrete and
embedded stud portion of an insulated concrete form
according to the invention;
FIG. 36 shows a perspective view of the concrete and
a embedded stud portion of an insulated concrete form
according to the invention;
FIG. 37 shows a partial perspective view of a metal
stud used in the invention;
FIG. 38 shows a plan view of an insulated concrete
form system according to the invention;
FIG. 39 shows an insulated concrete form corner unit
according to the invention; and
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FIG. 40 illustrates a manufacturer/customer method
of designing custom composite building panels according
to the invention.
DETAILED DESCRIPTION OF THE INVENTION
For the purpose of the description hereinafter, the
terms "upper," "lower," "inner", "outer", "right,"
"left," "vertical," "horizontal," "top," "bottom," and
derivatives thereof, shall relate to the invention as
oriented in the drawing Figures. However, it is to be
understood that the invention may assume alternate
variations and step sequences except where expressly
specified to the contrary. It is also to be understood
that the specific devices and processes, illustrated in
the attached drawings and described in the following
specification, is an exemplary embodiment of the present
invention. Hence, specific dimensions and other physical
characteristics related to the embodiment disclosed
herein are not to be considered as limiting the
invention. In describing the embodiments of the present
invention, reference will be made herein to the drawings
in which like numerals refer to like features of the
invention.
Other than where otherwise indicated, all numbers or
expressions referring to quantities, distances, or
measurements, etc. used in the specification and claims
are to be understood as modified in all instances by the
term "about." Accordingly, unless indicated to the
contrary, the numerical parameters set forth in the
following specification and attached claims are
approximations that can vary depending upon the desired
properties, which the present invention desires to
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obtain. At the very least, and not as an attempt to
limit the application of the doctrine of equivalents to
the scope of the claims, each numerical parameter should
at least be construed in light of the number of reported
significant digits and by applying ordinary rounding
techniques.
Notwithstanding that the numerical ranges and
parameters setting forth the broad scope of the invention
are approximations, the numerical values set forth in the
specific examples are reported as precisely as possible.
Any numerical values, however, inherently contain certain
errors necessarily resulting from the standard deviation
found in their respective measurement methods.
Also, it should be understood that any numerical
range recited herein is intended to include all sub-
ranges subsumed therein. For example, a range of "1 to
10" is intended to include all sub-ranges between and
including the recited minimum value of 1 and the recited
maximum value of 10; that is, having a minimum value
equal to or greater than 1 and a maximum value of equal
to or less than 10. Because the disclosed numerical
ranges are continuous, they include every value between
the minimum and maximum values. Unless expressly
indicated otherwise, the various numerical ranges
specified in this application are approximations.
As used herein, the term "expandable polymer matrix"
refers to a polymeric material in particulate or bead
form that is impregnated with a blowing agent such that
when the particulates and/or beads are placed in a mold
and heat is applied thereto, evaporation of the blowing
agent (as described below) effects the formation of a
cellular structure and/or an expanding cellular structure
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in the particulates and/or beads and the outer surfaces
of the particulates and/or beads fuse together to form a
continuous mass of polymeric material conforming to the
shape of the mold.
As used herein, the term "polymer" is meant to
encompass, without limitation, homopolymers, copolymers
and graft copolymers.
As used herein, the terms "(meth)acrylic" and
"(meth)acrylate" are meant to include both acrylic and
methacrylic acid derivatives, such as the corresponding
alkyl esters often referred to as acrylates and
(meth)acrylates, which the term "(meth)acrylate" is meant
to encompass.
The present invention provides pre-formed building
panels that include one or more reinforcing structural
elements or bars running longitudinally, which are
partially exposed, with the remainder of the reinforcing
structural element(s) partially encapsulated in an
expanded polymer matrix, which acts as a thermal break.
The reinforcing structural elements can be flanged
lengthwise on either side to provide attachment points
for external objects to the panel. Perforations in the
reinforcing structural elements which are encapsulated in
the expanded polymer matrix allow for fusion
perpendicularly. Perforations in the exposed portion of
the reinforcing structural element provide attachment
points for lateral bracing and utility installation. A
tongue and groove connection point design provides for
panel abutment, weep holes and attachment points for
external objects. Recessed areas on opposing panel ends
provide an area of member-to-member connection with "C"
channels running along the top and bottom of the
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structural member. Longitudinal holes through the
expanded polymer matrix are variable in diameter and
location and provide areas for placement of utilities,
lightening the structure and channels for venting of
gasses. Panel manufacture is accomplished through the
use of a semi-continuous or continuous molding process
allowing for variable panel lengths.
The embedded framing studs or floor joists used in
the invention can be made of any suitable material.
Suitable materials are those that add strength, stability
and structural integrity to the pre-formed building
panels. Such materials provide embedded framing studs
meeting the requirements of applicable test methods known
in the art, as non-limiting examples ASTM A 36/A 36M-05,
ASTM A 1011/A 1011M-05a, ASTM A 1008/A 1008M-05b, and
ASTM A 1003/A 1003M-05 for various types of steel.
Suitable materials include, but are not limited to
metals, construction grade plastics, composite materials,
ceramics, combinations thereof, and the like. Suitable
metals include, but are not limited to, aluminum, steel,
stainless steel, tungsten, molybdenum, iron and alloys
and combinations of such metals. In a particular
embodiment of the invention, the metal bars, studs,
joists and/or members are made of a light gauge metal.
Suitable construction grade plastics include, but
are not limited to reinforced thermoplastics, thermoset
resins, and reinforced thermoset resins. Thermoplastics
include polymers and polymer foams made up of materials
that can be repeatedly softened by heating and hardened
again on cooling. Suitable thermoplastic polymers
include, but are not limited to homopolymers and
copolymers of styrene, homopolymers and copolymers of C2
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to C20 olefins, C4 to C20 dienes, polyesters, polyamides,
homopolymers and copolymers of C2 to C20 (meth)acrylate
esters, polyetherimides, polycarbonates,
polyphenylethers, polyvinylchlorides, polyurethanes, and
combinations thereof.
Suitable thermoset resins are resins that when
heated to their cure point, undergo a chemical cross-
linking reaction causing them to solidify and hold their
shape rigidly, even at elevated temperatures. Suitable
thermoset resins include, but are not limited to alkyd
resins, epoxy resins, diallyl phthalate resins, melamine
resins, phenolic resins, polyester resins, urethane
resins, and urea, which can be crosslinked by reaction,
as non-limiting examples, with diols, trials, polyols,
and/or formaldehyde.
Reinforcing materials and/or fillers that can be
incorporated into the thermoplastics and/or thermoset
resins include, but are not limited to carbon fibers,
aramid fibers, glass fibers, metal fibers, woven fabric
or structures of the mentioned fibers, fiberglass, carbon
black, graphite, clays, calcium carbonate, titanium
dioxide, woven fabric or structures of the above-
referenced fibers, and combinations thereof.
A non-limiting example of construction grade
plastics are thermosetting polyester or vinyl ester resin
systems reinforced with fiberglass that meet the
requirements of required test methods known in the art,
non-limiting examples being ASTM D790, ASTM D695, ASTM
D3039 and ASTM D638.
The thermoplastics and thermoset resins can
optionally include other additives, as a non-limiting
example ultraviolet (UV) stabilizers, heat stabilizers,
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flame retardants, structural enhancements, biocides, and
combinations thereof.
The embedded framing studs or embedded floor joists
(reinforcing embedded bars) can have a thickness of at
least 0.4 mm, in some cases at least 0.5 mm, in other
cases at least 0.75 mm, in some instances at least 1 mm,
in other instances at least 1.25 mm and in some
circumstances at least 1.5 mm and can have a thickness of
up to 10 mm, in some cases up to 8 mm, in other cases up
to 6 mm, in some instances up to 4 mm and in other cases
up to 2 mm. The thickness of the embedded framing studs
or embedded floor joists will depend on the intended use
of the pre-formed building panel.
In an embodiment of the invention, the embedded
reinforcing bars, studs, joists and/or members have holes
or openings along their length to facilitate fusion of
the expanded plastic material and to reduce any thermal
bridging effects in the reinforcing bars, studs, joists
and/or members.
The expanded polymer matrix makes up the expanded
polymer body described herein below. The expanded
polymer matrix is typically molded from expandable
thermoplastic particles. These expandable thermoplastic
particles are made from any suitable thermoplastic
homopolymer or copolymer. Particularly suitable for use
are homopolymers derived from vinyl aromatic monomers
including styrene, isopropylstyrene, alpha-methylstyrene,
nuclear methylstyrenes, chlorostyrene, tert-butylstyrene,
and the like, as well as copolymers prepared by the
copolymerization of at least one vinyl aromatic monomer
as described above with one or more other monomers, non-
limiting examples being divinylbenzene, conjugated dienes
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(non-limiting examples being butadiene, isoprene, 1, 3-
and 2,4- hexadiene), alkyl methacrylates, alkyl
acrylates, acrylonitrile, and maleic anhydride, wherein
the vinyl aromatic monomer is present in at least 50% by
weight of the copolymer. In an embodiment of the
invention, styrenic polymers are used, particularly
polystyrene. However, other suitable polymers can be
used, such as polyolef ins (e.g. polyethylene,
polypropylene), polycarbonates, polyphenylene oxides, and
mixtures thereof.
, In a particular embodiment of the invention, the
expandable thermoplastic particles are expandable
polystyrene (EPS) particles. These particles can be in
the form of beads, granules, or other particles
convenient for the expansion and molding operations.
Particles polymerized in an aqueous suspension process
are essentially spherical and are useful for molding the
expanded polymer body described herein below. These
particles can be screened so that their size ranges from
about 0.008 inches (0.2 mm) to about 0.1 inches (2.5 mm).
The expandable thermoplastic particles can be
impregnated using any conventional method with a suitable
blowing agent. As a non-limiting example, the
impregnation can be achieved by adding the blowing agent
to the aqueous suspension during the polymerization of
the polymer, or alternatively by re-suspending the
polymer particles in an aqueous medium and then
incorporating the blowing agent as taught in U.S. Pat.
No. 2,983,692. Any gaseous material or material which
will produce gases on heating can be used as the blowing
agent. Conventional blowing agents include aliphatic
hydrocarbons containing 4 to 6 carbon atoms in the
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molecule, such as butanes, pentanes, hexanes, and the halogenated
hydrocarbons,
e.g. CFC's and HCFC'S, which boil at a temperature below the softening point
of the
polymer chosen. Mixtures of these aliphatic hydrocarbon blowing agents can
also be
used.
Alternatively, water can be blended with these aliphatic hydrocarbons blowing
agents or water can be used as the sole blowing agent as taught in U.S. Pat.
Nos.
6,127,439; 6,160,027; and 6,242,540 in these patents, water-retaining agents
are
used. The weight percentage of water for use as the blowing agent can range
from 1
to 20
The impregnated thermoplastic particles are generally pre-expanded to a
density of at least 0.5 lb/ft.3 (0.008 g/cc), in some cases at least 1 lb/ft3
(0.016 g/cc),
in other cases at least 1.25 lb/ft3 (0.02 g/cc), in some situations at least
1.5 lb/ft3
(0.024 g/cc), in other situations at least 2 lb/ft3 (0.032 g/cc), and in some
instances at
least about 3 lb/ft3 (0.048 g/cc). Also, the density of the impregnated pre-
expanded
particles can be up to 35 lb/ft3 (0.56 g/cc), in some cases up to 30 lb/ft3
(0.48 g/cc),
and in other cases up to 25 lb/ft3 (0.4 g/cc). The density of the impregnated
pre-
expanded particles can be any value or range between any of the values recited
above. The pre-expansion step is conventionally carried out by heating the
impregnated beads via any conventional heating medium, such as steam, hot air,
hot
water, or radiant heat. One generally accepted method for accomplishing the
pre-
expansion of
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impregnated thermoplastic particles is taught in U.S. Pat. No. 3,023,175.
The impregnated thermoplastic particles can be foamed cellular polymer
particles as taught in U.S. patent application Ser. No. 10/021,716. The foamed
cellular particles can be polystyrene that are pre-expanded and contain a
volatile
blowing agent at a level of less than 6.0 weight percent, in some cases
ranging from
about 2.0 wt % to about 5.0 wt %, and in other cases ranging from about 2.5 wt
% to
about 3.5 wt % based on the weight of the polymer.
An interpolymer of a polyolefin and in situ polymerized vinyl aromatic
monomers that can be included in the expandable thermoplastic resin according
to
the invention is disclosed in U.S. Pat. Nos. 4,303,756 and 4,303,757 and U.S.
Application Publication 2004/0152795. A non-limiting example of interpolymers
that
can be used in the present invention include those available under the trade
name
ARCEL®, available from NOVA Chemicals Inc., Pittsburgh, Pa. and
PIOCELAN®, available from Sekisui Plastics Co., Ltd., Tokyo, Japan.
The expanded polymer matrix can include customary ingredients and
additives, such as pigments, dyes, colorants, plasticizers, mold release
agents,
stabilizers, ultraviolet light absorbers, mold prevention agents,
antioxidants, and so
on. Typical pigments include, without limitation, inorganic pigments such as
carbon
black, graphite, expandable graphite, zinc oxide, titanium dioxide, and iron
oxide, as
well as organic
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pigments such as quinacridone reds and violets and copper
phthalocyanine blues and greens.
In a particular embodiment of the invention the
pigment is carbon black, a non-limiting example of such a
material being EPS SILVER , available from NOVA Chemicals
Inc.
In another particular embodiment of the invention
the pigment is graphite, a non-limiting example of such a
material being NEOPOR , available from BASF
Aktiengesellschaft Corp., Ludwigshafen am Rhein, Germany.
When materials such as carbon black and/or graphite
are included in the polymer particles, improved
insulating properties, as exemplified by higher R values
for materials containing carbon black or graphite (as
determined using ASTM - C578), are provided. As such,
the R value of the expanded polymer particles containing
carbon black and/or graphite or materials made from such
polymer particles are at least 5% higher than observed
for particles or resulting articles that do not contain
carbon black and/or graphite.
The pre-expanded particles or "pre-puff" are heated
in a closed mold in the semi-continuous or continuous
molding process described below to form the pre-formed
building panels according to the invention.
The expanded polymer body used in the invention
include holes, conduits or chases that molded into and
extend along the length of the expanded polymer body. In
an embodiment of the invention, the holes, conduits or
chases are used for providing access, ways for utilities,
such as wiring, plumbing and exhaust through the walls,
ceilings, floors and roofs constructed according to the
present invention.
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In another embodiment of the invention, the wall
units, floor units and expanded polymer panels or central
body have a male "tongue" edge and a female "groove" edge
that facilitates a "tongue and groove" union of two
matching wall units, floor units and expanded polymer
panels. The tongue and groove union can be non-linear
and can provide for a weep hole and/or larger opening to
accommodate plumbing lines. Typically the tongue and
groove union provides a flat surface at the union to
allow for easy application of sealing tape to seal the
union or joint.
An embodiment of the present invention provides wall
units and wall systems. As shown in FIG. 1, wall unit 10
includes expanded polymer body 12 (central body), left
facing embedded metal studs 14, and right facing embedded
metal studs 16 (reinforcing embed bars). Expanded
polymer body 12 includes openings 18 that traverse all or
part of the length of expanded polymer body 12. The
embedded metal studs 14 and 16 have embedded ends 20 and
22 respectively that do not touch outer surface 24 of
expanded polymer body 12. The embedded metal studs 14
and 16 also have exposed ends 26 and 28 respectively that
extend from inner surface 30 of expanded polymer body 12.
Expanded polymer body 12 can have a thickness 5,
measured as the distance from inner surface 30 to outer
surface 24 of at least 2, in some cases at least 2.5, and
in other cases at least 3 cm and can be up to 10, in some
cases up to 8, and in other cases up to 6 cm from inner
surface 30 of expanded polymer body 12. Embedded ends 26
and 28 can extend any of the distances or can range
between any of the distances recited above from inner
surface 30.
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Exposed ends 26 and 28 extend at least 1, in some
cases at least 2, and in other cases at least 3 cm away
from inner surface 30 of expanded polymer body 12. Also,
Exposed ends 26 and 28 can extend up to 60, in some cases
up to 40, and in other cases up to 20 cm away from inner
surface 30 of expanded polymer body 12. In many cases
,
exposed ends 26 and 28 extend from polymer body 12 a
distance sufficient to allow utilities to be run along
inner surface 30 as described herein. Exposed ends 26
and 28 can extend any of the distances or can range
between any of the distances recited above from inner
surface 30.
Embedded ends 20 and 22 extend at least 1, in some
cases at least 2, and in other cases at least 3 cm into
expanded polymer body 12 away from inner surface 30.
Also, Embedded ends 20 and 22 can extend up to 10, in
some cases up to 8, and in other cases up to 6 cm away
from inner surface 30 into expanded polymer body 12. In
many cases, embedded ends 20 and 22 extend a distance
into expanded polymer body 12 such that embedded ends 20
and 22 do not contact outer surface 24. The depth
defined between outer surface 24 and embedded ends 20 and
22 define a thermal break. Embedded ends 26 and 28 can
extend any of the distances or can range between any of
the distances recited above from inner surface 30 into
polymer body 12.
In another embodiment of the invention, embedded
ends 20 and 22 can extend from 1/10 to 9/10, in some
cases 1/3 to 2/3 and in other cases 1/4 to 3/4 of the
thickness of expanded polymer body 12 into expanded
polymer body 12.
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In an embodiment of the invention, embedded metal
studs 14 and 16 have a cross-sectional shape that
includes embedding lengths 34 and 36, embedded ends 20
and 22, and exposed ends 26 and 28. The
orientation of
embedded metal studs 14 and 16 is referenced by the
direction of open ends 38 and 40. In an embodiment of
the invention, open ends 38 and 40 are oriented away from
each other. In this embodiment, wall unit 10 has greater
rigidity and is easier to handle without bending.
The spacing between each of embedded metal studs 14
and 16 is typically adapted to be consistent with local
construction codes or methods, but can be modified to
suit special needs. As such, the spacing between the
metal studs can be at least 10, in some instances at
least 25 and in some cases at least 30 cm and can be up
to 110, in some cases up to 100, in other cases up to 75,
and in some instances up to 60 cm measured from a
midpoint of exposed end 26 to a midpoint of exposed end
28. The spacing between embedded metal studs 14 and 16
can be any distance or range between any of the distances
recited above.
Openings 18 can have various cross-sectional shapes,
non-limiting examples being round, oval, elliptical,
square, rectangular, triangular, hexagonal or octagonal.
The cross-sectional size of openings 18 can be uniform or
they can vary independently of each other with regard to
size and location relative to inner surface 30 and outer
surface 24. The spacing between each opening 18 can be
at least 5 and in some cases at least 10 cm and can be up
to 110, in some cases up to 100, in other cases up to 75,
and in some instances up to 60 cm measured from a
midpoint of one opening 18 to an adjacent opening 18.
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The spacing between openings 18 can independently be any
distance or range between any of the distances recited
above.
The cross-sectional area of openings 18 can also
vary independently one from another or they can be
uniform. The cross-sectional area of openings 18 is
limited by the dimensions of expanded polymer body 12, as
openings 18 will fit within the dimensions of expanded
polymer body 12. The cross-sectional area of openings 18
can independently be at least 1, in some cases at least
5, and in other cases at least 9 cm2 and can be up to 130,
in some cases up to 100, in other cases up to 75 cm2. The
cross-sectional area of openings 18 can independently be
any value or range between any of the values recited
above.
As shown in FIG.1, expanded polymer body 12 can
extend for a distance with alternating embedded metal
studs 14 and 16 placed therein. The length of wall unit
10 can be any length that allows for safe handling and
minimal damage to wall unit 10. The length of wall unit
10, defined as the distance from receiving end 27 to male
terminal end 21, can typically be at least 1, in some
cases at least 1.5, and in other cases at least 2 m and
can be up to 25, in some cases up to 20, in other cases
up to 15, in some instances up to 10 and in other
instances up to 5 m. The length of wall unit 10 can be
any value or can range between any of the values recited
above. In some embodiments of the invention, each end of
wall unit 10 is terminated with an embedded metal stud.
The height of wall unit 10 can be any height that
allows for safe handling and minimal damage to wall unit
10. The height of wall unit 10 is determined by the
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length of embedded metal studs 14 and 16. The height of
wall unit 10 can be at least 1 and in some cases at least
1.5 m and can be up to 3 M and in some cases up to 2.5 m.
In some instances, in order to add stability to wall unit
10, reinforcing cross-members (not shown) can be attached
to embedded metal studs 14 and 16. The height of wall
unit 10 can be any value or can range between any of the
values recited above.
As shown in FIG. 1, expanded polymer body 12 has a
finite length 72 and has a male terminal end 21 that
includes forward edge 23 and trailing edge 25 and a
receiving end 27 which includes recessed section 29 and
extended section 31, which is adapted to receive forward
edge 23, and trailing edge 25. Typically, lengths of
wall units 10 are interconnected by inserting a forward
edge 23 from a first wall unit 10 into a recessed section
29 a second wall unit 10. In this manner, a larger wall
section containing any number of wall units can be
assembled and/or arrayed.
Wall unit 10 is typically part of an overall wall
system 21 as shown in FIGS. 3-11. A bottom end of
embedded metal studs 14 and 16 are seated in and attached
to a bottom track 44 and a top slip track 42. This
configuration leads to the formation of bottom channel 52
and top channel 54. Channels 52 and 54 can be filled
with correspondingly shaped expanded polymer material, or
alternatively with a molding shaped to fit in channels 52
or 54.
As a non-limiting example molding 58 can be inserted
into top channel 54 and attached to top slip track 42 by
inserting fasteners 60 into holes 62 in top slip track 62
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as shown in FIGS. 10 and 11. Molding 58 provides a
thermal break to the exposed metal track.
Channels 52 and 54 provide an advantageous feature
of the present invention as the channels at the ends of
the panels expose the embedded metal studs 14 and 16 on
both sides. This feature over comes a basic structural
problem in the prior art by providing a positive
mechanical connection to both sides of the embedded metal
studs when top slip track 42 and bottom track 44 are
installed.
Referring to FIGS. 3, 5, and 7-9, embedded metal
studs 14 and 16 can have utility holes 46 spaced along
their length. Utility holes 46 are useful for
accommodating utilities such as wiring for electricity,
telephone, cable television, speakers, and other
electronic devices, gas lines and water lines (as shown
particularly in FIG. 9). Utility holes 46 can have
various cross-sectional shapes, non-limiting examples
being round, oval, elliptical, square, rectangular,
triangular, hexagonal or octagonal. The cross-sectional
area of Utility holes 46 can also vary independently one
from another or they can be uniform. The cross-sectional
area of utility holes 46 is limited by the dimensions of
embedded metal studs 14 and 16, as utility holes 46 will
fit within their dimensions and not significantly detract
from their structural integrity and strength. The cross-
sectional area of utility holes 46 can independently be
at least 1, in some cases at least 2, and in other cases
at least 5 cm2 and can be up to 30, in some cases up to
25, in other cases up to 20 cm2. The cross-sectional area
of openings 18 can independently be any value or range
between any of the values recited above.
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In an embodiment of the invention, utility holes 46
can have a flanged and in many cases a rolled flange
surface to provided added strength to the embedded metal
studs. The flanged holes allow for the use of lighter
gauge materials to achieve the same structural
properties.
A wall system 21 is shown in FIGS. 5-8, where three
wall units are connected. Where the ends of two wall
units meet to form a corner, an outside corner attachment
47 secures the ends of the two wall units together.
Also, additional metal studs 49 can be included to add
strength to the formed corners. Thus the wall system
includes interconnecting bottom 44 and top 42 slip tracks
and end embedded metal studs 51 secured together at
corner attachment units that extend along the height of
each wall unit.
Openings for windows and doors are provided by
framing the ends of the opening with two or more embedded
metal studs placed adjacent to each other (shown as 53).
Upper member 55 and lower member 57 are connected to the
embedded metal studs to form a framed opening. The
openings are adapted to readily accept pre-manufactured
windows and doors.
The strength and integrity of wall system 21 can be
enhanced by including spanner bars 61 that are arranged
to pass through openings, such as utility holes 46 in
embedded metal studs 14 and 16. Spanner bars 61 are
attached to embedded metal studs 14 and 16 and are
arranged, as shown, in a generally perpendicular
relationship to metal studs 14 and 16, although spanner
bars 61 can be arranged to form any suitable angle with
embedded metal studs 14 and 16 that enhances the strength
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,
and integrity or wall system 21. Spanner bars and metal studs that can be
incorporated in the invention include those available under the trade name
TRADEREADY® SPAZZER® available from Dietrich Industries, Inc.,
Pittsburgh, Pa. as well as those disclosed in U.S. Pat. Nos. 5,784,850 and
6,021,618.
The various metal structural parts in wall system 21 can be secured or
attached to one another by way of welds 71 and/or screws 73.
Particular advantages of the present wall units and wall systems include the
ability to easily run utilities prior to attaching a finish surface to the
exposed ends of
the embedded metal studs. The exposed metal studs facilitate field structural
framing
changes and additions and leave the structural portions of the assembly
exposed for
local building officials to inspect the framing.
Referring to FIG. 9, in an embodiment of the invention, wall unit 10 includes
expanded polymer body 12 (central body), right facing embedded metal studs 16
(reinforcing embed bars), which include flanges 11 and have utility holes 46
located
in an exposed portion of embedded studs 16, expansion holes 13 in an embedded
portion of embedded studs 16 and embedded end 22, which, does not touch outer
surface 24 of expanded polymer body 12. The embedded metal studs 16 also have
exposed end 28 respectively that extends from inner surface 30 of expanded
polymer body 12.
Expansion holes 13 are useful in that as expanded polymer body 12 is
molded, the polymer matrix expands through expansion holes 13 and the
expanding
polymer fuses. This allows the polymer matrix to encase and hold
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embedded studs 16 by way of the fusion in the expanding
polymer. In an embodiment of the invention, expansion
holes 13 can have a flanged and in many cases a rolled
flange surface to provided added strength to the embedded
metal studs.
A utility space defined by inner surface 30 of
expanded polymer body 12 and flanges 11 adapted for
accommodating utilities is provided. Typically, flanges
11 have a finish surface (as described herein) attached
to them, a side of which further defines the utility
space.
In an embodiment of the invention, the utility space
is adapted and dimensioned to receive standard and/or
pre-manufactured components, such as windows, doors and
medicine cabinets as well as customized cabinets and
shelving.
In an embodiment of the invention, utility holes 46
are adapted to allow utilities (as shown, electrical line
15) to be run in a transverse direction relative to
embedded studs 16.
The utilities can be one or more selected from water
lines (either potable, or as a non-limiting example hot
water lines for radiant heating), waste lines, chases,
telephone lines, cable television lines, computer lines,
fiber optic cables, satellite dish communication lines,
antenna lines, electrical lines, ductwork, and gas lines.
In a particular embodiment of the invention, wall
unit 10 is attached to bottom track 44. In this
embodiment, bottom track 44 is adapted to hold a volume
at least equivalent to the volume of the expanded polymer
matrix in expanded polymer body 12, in liquid or molten
form. In some instances, this volume can be defined by
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bottom 101 and sides 103 of bottom track 44 and the
portions of embedded studs 16 within the space defined by
bottom track 44.
Non-limiting examples of suitable finish surfaces
include wood, rigid plastics, wood paneling, concrete
panels, cement panels, drywall, sheetrock, particle
board, rigid plastic panels, a metal lath, combinations
thereof or any other suitable material having decorating
and/or structural functions.
Further, the air space between the inner surface of
the expanded polymer body and the finish surface allows
for improved air circulation, which can minimize or
prevent mildew. Additionally, because the metal studs
are not in direct contact with the outer surface, thermal
bridging via the highly conductive embedded metal studs
is avoided and insulation properties are improved.
The present invention also provides floor units and
floor systems that include composite floor panels. The
floor panels generally include a central body,
substantially parallelepipedic in shape, containing an
expanded polymer matrix, having opposite faces, a top
surface, and an opposing bottom surface; and two or more
embedded floor joists longitudinally extending across the
central body between the opposite faces, having a first
end embedded in the expanded polymer matrix, having a
first transverse member extending from the first end
generally contacting or extending above the top surface,
a second end extending away from the bottom surface of
the central body having a second transverse member
extending from the second end, and one or more expansion
holes located in the embedded floor joists between the
first end of the embedded floor joists and the bottom
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surface of the central body. The central body contains a
polymer matrix as described above that expands through
the expansion holes. The embedded floor joists include
one or more utility holes located in the embedded joists
between the bottom surface of the central body and the
second end of the embedded joists and the space defined
by the bottom surface of the central body and the second
ends of the embedded floor joists is adapted for
accommodating utility lines. The composite floor panel
is positioned generally perpendicular to a structural
wall and/or foundation.
As shown in FIG. 12, floor unit 90 includes
expandable polymer panel 92 (central body) and embedded
metal joists 94 and 96 (reinforcing embedded bars).
Expandable polymer panel 92 includes openings 98 that
traverse all or part of the length of expanded polymer
panel 92. The embedded metal joists 94 and 96 have
embedded ends 104 and 106 respectively that are in
contact with top surface 102 of expanded polymer panel
92. The embedded metal joists 94 and 96 also have
exposed ends 108 and 110 respectively that extend from
bottom surface 100 of expanded polymer panel 92.
Embedded metal joists 94 and 96 include first
transverse members 124 and 126 respectively extending
from embedded ends 104 and 106 respectively, which are
generally in contact with top surface 102 and exposed
ends 108 and 110 include second transverse members 128
and 129 respectively, which extend from exposed ends 108
and 110 respectively. The space defined by bottom surface
100 of expanded polymer panel 92 and the exposed ends 108
and 110 and second transverse members 128 and 129 of
embedded metal joists 94 and 96 can be oriented to accept
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ductwork placed between embedded metal joists 94 and 96
adjacent bottom surface 100.
Expanded polymer panel 92 can have a thickness,
measured as the distance from top surface 102 to bottom
surface 100 similar in dimensions to that described above
regarding expanded polymer body 12.
Exposed ends 108 and 110 extend at least 1, in some
cases at least 2, and in other cases at least 3 cm away
from bottom surface 100 of expanded polymer panel 92.
Also, Exposed ends 108 and 110 can extend up to 60, in
some cases up to 40, and in other cases up to 20 cm away
from bottom surface 100 of expanded polymer panel 92.
Exposed ends 108 and 110 can extend any of the distances
or can range between any of the distances recited above
from bottom surface 100.
In an embodiment of the invention, embedded metal
joists 94 and 96 have a cross-sectional shape that
includes embedding lengths 114 and 116, embedded ends 104
and 106, and exposed ends 108 and 110. The orientation
of embedded metal joists 94 and 96 is referenced by the
direction of open ends 118 and 120. In an embodiment of
the invention, open ends 118 and 120 are oriented toward
each other. In this embodiment, floor unit 90 is adapted
to accept ductwork. As a non-limiting example, a HVAC
duct can be installed along the length of embedded metal
joists 94 and 96.
As used herein, the term "ductwork" refers to any
tube, pipe, channel or other enclosure through which air
can flow from a source to a receiving space; non-limiting
examples being air flowing from heating and/or air-
conditioning equipment to a room, make-up air flowing
from a room to heating and/or air-conditioning equipment,
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fresh air flowing to an enclosed space, and/or waste air
flowing from an enclosed space to a location outside of
the enclosed space. In some embodiments, ductwork
includes generally rectangular metal tubes that are
located below and extend generally adjacent to a floor.
The spacing between each of embedded metal joists 94
and 96 can be as described regarding embedded metal studs
14 and 16 in wall unit 10.
Openings 98 can have various cross-sectional shapes,
and similar spacing and cross-sectional area as described
regarding openings 18 in expanded polymer body 12.
As shown in FIG.12, expanded polymer panel 92 can
extend for a distance with alternating embedded metal
joists 94 and 96 placed therein. The length of floor
unit 90 can be any length that allows for safe handling
and minimal damage to floor unit 90. The length of floor
unit 90 can be as described regarding the length of wall
unit 10. In some embodiments, an end of floor unit 90
can be terminated with an embedded metal joist.
As shown in FIG. 12, expanded polymer panel 92 has a
finite length and has a male terminal end 91 that
includes forward edge 93 and trailing edge 95 and a
receiving end 97 which includes recessed section 99 and
extended section 101, which is adapted to receive forward
edge 93, and trailing edge 95. Typically, lengths of
floor units 90 are interconnected by inserting a forward
edge 93 from a first floor unit 90 into a recessed
section 99 from a second floor unit 90. In this manner,
a larger floor section containing any number of floor
units can be assembled and/or arrayed.
The width of floor unit 90 can be any width that
allows for safe handling and minimal damage to floor unit
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90. The width of floor unit 90 is determined by the
length of embedded metal joists 94 and 96. The width of
floor unit 90 can be at least 1 and in some cases at
least 1.5 m and can be up to 3 m and in some cases up to
2.5 m. In some instances, in order to add stability to
floor unit 90, reinforcing cross-members (not shown) can
be attached to embedded metal joists 94 and 96. The
width of floor unit 90 can be any value or can range
between any of the values recited above.
Floor unit 90 is typically part of an overall floor
system that includes a plurality of the composite floor
panels described herein, where the male ends include a
tongue edge and the female ends include a groove arrayed
such that a tongue and/or groove of each panel is in
sufficient contact with a corresponding tongue and/or
groove of another panel to form a plane. The established
plane extends laterally from a foundation and/or a
structural wall.
In the present floor system, ductwork can be
attached to the reinforcing metal bars of at least one
composite floor panel.
Additionally, a flooring material can be attached to
or in contact with one or more of the first transverse
members of the composite floor panels. Any suitable
flooring material can be used in the invention. Suitable
flooring materials are materials that can be attached to
the transverse members and cover at least a portion of
the expanded polymer panel. Suitable flooring materials
include, but are not limited to plywood, wood planks,
tongue and grooved wood floor sections, sheet metal,
sheets of structural plastics, stone, ceramic, cement,
concrete, and combinations thereof.
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Generally, the floor system forms a plane that
extends laterally from a foundation and/or a structural
wall.
FIGS. 13 and 14 show floor systems 140 and 141
respectively. Floor system 140 is established by
contacting forward edge 93 with recessed section 99 to
form a continuous floor 142. Like features of the
individual floor panels are labeled as indicated above.
As described above, various shaped types of ductwork can
be secured in the space defined by bottom surface 100 of
expanded polymer panel 92 and the exposed ends 108 and
110 and second transverse members 128 and 129 of embedded
metal joists 94 and 96. As non-limiting examples,
rectangular ventilation duct 147 is shown in FIG. 13 and
circular air duct 148 is shown in FIG. 14.
As shown in the embodiment of FIG. 13, tongue and
groove wood flooring 149 is placed over floor units 90
and attached to first transverse members 124 and 126. In
an alternative embodiment (not shown) a plywood, plastic,
particle board or other suitable sub-floor can be
attached to first transverse members 124 and 126 and
tongue and groove wood flooring 149 attached thereto.
As shown in FIG. 3, an end of embedded metal joists
94 and 96 are seated in and attached to a joist rim 122
and a second joist rim is attached to the other end of
embedded metal joists 94 and 96. A floor base 149,
typically plywood, particle board or other supporting
surface or flooring material, can be attached to first
transverse members 124 and/or 126.
Referring to FIG. 3, embedded metal joists 94 and 96
have utility holes 127 spaced along their length.
Utility holes 127 are useful for accommodating wiring for
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electricity, telephone, cable television, speakers, and
other electronic devices. Utility holes 127 can have
various cross-sectional shapes, non-limiting examples
being round, oval, elliptical, square, rectangular,
triangular, hexagonal or octagonal. The cross-sectional
area of Utility holes 127 can also vary independently one
from another or they can be uniform. The cross-sectional
area of utility holes 127 is limited by the dimensions of
embedded metal joists 94 and 96, as utility holes 127
will fit within their dimensions and not significantly
detract from their structural integrity and strength.
The cross-sectional area of utility holes 127 can
independently be at least 1, in some cases at least 2,
and in other cases at least 5 cm2 and can be up to 30, in
some cases up to 25, in other cases up to 20 cm2. The
cross-sectional area of utility holes 127 can
independently be any value or range between any of the
values recited above.
Expansion holes 113, as mentioned above are useful
in that as expanded polymer body 92 is molded, the
polymer matrix expands through expansion holes 113 and
the expanding polymer fuses. This allows the polymer
matrix to encase and hold embedded studs 94 and 96 by way
of the fusion in the expanding polymer. In an embodiment
of the invention, expansion holes 113 can have a flanged
and in many cases a rolled flange surface to provided
added strength to the embedded metal studs.
In an embodiment of the invention, the floor system
can be placed on a foundation. However, because
foundations are rarely perfectly level, a level track can
be attached to the foundation prior to placement of the
floor system. The level track includes a top surface
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having a length and two side rails extending from
opposing edges of the top surface, where the width of the
top surface is greater than a width of the foundation and
the length of the top surface is generally about the same
as the length of the foundation. The level track is
generally attached to the foundation by placing the level
track over the foundation with the side rails generally
contacting the sides of the foundation, situating the top
surface such that it conforms to level and permanently
attaching the level track to the foundation. A rim joist
can be used to aid in attaching the top surface to an end
of the plurality of composite floor panels.
More particularly, a level track 128 can be attached
to foundation 130 prior to placement of the floor system
(see FIGS. 3 and 4). Level track 128 can be placed on
foundation 128 and leveled. The level is made permanent
by fastening level track 128 to foundation 130 by using
fasteners 131 (nails shown, although screws or other
suitable devices can be used) via fastening holes 132.
Screws 133 can also be used to attach level track 128 to
foundation 130 via screw holes 135. Some of screw holes
135 can be used in conjunction with screws 133 to attach
a bottom lip of joist rim 122 to level track 128. Screws
133 can also maintain the level position of level track
128 until a more permanent positioning is achieved.
Alternatively or additionally mortar can be applied via
mortar holes 134 to fill the space between level track
128 and the top of foundation 130. After level track 128
has been attached and/or the mortar has sufficiently set,
the flooring system can be fastened to the foundation.
Level track 128 includes side rails 137, which are
adapted to extend over a portion of foundation 130. The
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width of level track 128 is the transverse distance of a
top portion of level track 128 from one side rail 137 to
the other. The width of level track 128 is typically
slightly larger than the width of foundation 130. The
width of level track 128 can be at least 10 cm, in some
cases at least 15 cm, in other cases at least 20 cm and
in some instances at least 21 cm. Also, the width of
level track 128 can be up to 40 cm, in some cases up to
35 cm, and in other cases up to 30 cm. The width of
level track 128 can be any value or range between any of
the values recited above.
The length of side rail 137 is the distance it
extends from a top portion of level track 128 and is
sufficient in length to allow for proper leveling of
level track 128 and attachment to foundation 130 via
fasteners 131 and fastening holes 132. The length of
side rail 137 can be at least 4 cm, in some cases at
least 5 cm, and in other cases at least 7 cm. Also, the
length of side rail 137 can be up to 20 cm, in some cases
up to 15 cm, and in other cases up to 12 cm. The length
of side rail 137 can be any value or range between any of
the values recited above.
An embodiment of the invention relates to a floor or
tilt up insulated panel that is adapted to act as a
concrete I-beam form. As shown in FIG. 15, I-beam panel
140 includes expanded polymer form 142 (central body) and
embedded metal members 144 and 146 (embedded reinforcing
bars). Expanded polymer form 142 includes openings 148
that traverse all or part of the length of expanded
polymer form 142. The embedded metal members 144 and 146
have embedded ends 152 and 156 respectively that are in
contact with inner face 150 of expanded polymer form 142.
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The embedded metal members 144 and 146 also have exposed
ends 158 and 160 respectively that extend from outer face
162 of expanded polymer form 142.
Expanded polymer form 142 can have a thickness,
measured as the distance from inner face 150 to outer
face 162 similar in dimensions to that described above
regarding expanded polymer body 12.
Exposed ends 158 and 160 extend at least 1, in some
cases at least 2, and in other cases at least 3 cm away
outer face 162 of expanded polymer form 142. Also,
Exposed ends 158 and 160 can extend up to 60, in some
cases up to 40, and in other cases up to 20 cm away from
outer face 162 of expanded polymer form 142. Exposed
ends 158 and 160 can extend any of the distances or can
range between any of the distances recited above from
outer face 100.
In an embodiment of the invention, embedded metal
members 144 and 146 have a cross-sectional shape that
includes embedding lengths 164 and 166, embedded ends 152
and 156, and exposed ends 158 and 160. The orientation
of embedded metal members 144 and 146 is referenced by
the direction of open ends 168 and 170. In an embodiment
of the invention, open ends 168 and 170 are oriented
toward each other. In this embodiment, I-beam panel 140
is adapted to be imbedded in concrete that can be applied
to outer face 162.
The spacing between each of embedded metal members
144 and 146 can be as described regarding embedded metal
studs 14 and 16 in wall unit 10.
Openings 148 can have various cross-sectional
shapes, and similar spacing and cross-sectional area as
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described regarding openings 18 in expanded polymer body
12.
As shown in FIG. 15, expanded polymer panel 140 has
a finite length and has a male terminal end 170 that
includes forward edge 172 and trailing edge 174 and a
receiving end 176 which includes recessed section 178,
which is adapted to receive forward edge 172, and
protruding edge 180. Typically, lengths of I-beam panels
140 are interconnected by inserting a forward edge 172
from a first I-beam panel 140 into a recessed section 178
of a second I-beam panel. In this manner, a larger roof,
ceiling, floor or wall section containing any number of
I-beam panels can be assembled and/or arrayed. The width
of I-beam panel 140, measured as the distance from
protruding edge 180 to trailing edge 174 can typically be
at least 20, in some cases at least 30, and in other
cases at least 35 cm and can be up to 150, in some cases
up to 135, and in other cases up to 125 cm. The width of
I-beam panel 140 can be any value or can range between
any of the values recited above.
I-beam panel 140 includes I-beam channel 182. The
present I-beam panel is advantageous when compared to
prior art systems in that the connection between adjacent
panels in the prior art is provided along the thin
section of expanded polymer below I-beam channel 182.
The resulting thin edge is prone to damage and/or
breakage during shipment and handling. The I-beam panel
of the present invention eliminates this problem by
molding in the I-beam channel, eliminating the exposure
of a thin edge section to potential damage.
In an embodiment of the invention, rebar or other
concrete reinforcing rods can be placed in I-beam channel
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182 in order to strengthen and reinforce a concrete I-
beam formed within I-beam channel 182.
In another embodiment of the invention shown in FIG.
16, instead of I-beam channel 182, I-beam panel 141
includes channel 183. Channel 183 is adapted to accept
round ductwork or other mechanical and utility parts and
devices and/or can be filled with concrete as described
above.
An example of an I-beam system 200 according to the
invention is shown in FIG. 17, where four I-beam panels
140 are connected by inserting a forward edge 172 from a
first I-beam panel 140 into a recessed section 178 of a
second I-beam panel. Concrete is poured, finished and
set to form a concrete layer 202 that includes concrete
I-beams 204, which are formed in I-beam channels 182.
The embodiment shown in FIG. 17 is an alternating
embodiment, where the direction of I-beam channel 182 of
each I-beam panel 140 alternately faces toward concrete
layer 202 and includes concrete I-beam 204 or faces away
from concrete layer 202 and I-beam channel 182 does not
contain concrete. In an embodiment of the invention, the
facing away I-beam panel can be I-beam panel 141.
Alternatively, every I-beam panel 140 could face concrete
layer 202 and include concrete I-beam 204.
In the embodiment shown, exposed ends 158 and 160
are either embedded in concrete layer 202 or are exposed.
The exposed ends 158 and 160 are available as attachment
points for a finish surface 210, which can include wood,
rigid plastics, wood paneling, concrete panels, cement
panels, drywall, sheetrock, particle board, rigid plastic
panels, or any other suitable material having decorating
and/or structural functions or other construction
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substrates 210. The attachment is typically accomplished
through the use of screws, nails, adhesive or other
fasteners known in the art.
In an embodiment of the invention, I-beam system 200
is assembled on a flat surface and a first end is lifted
while a second end remains stationary resulting in
orienting I-beam system 200 generally perpendicular to
the flat surface. This is often referred to as "tilting
a wall" in the art and in this embodiment of the
invention, I-beam system 200 is referred to as a "tilt-
wall."
In another embodiment of the invention, I-beam
system 200 can be used as a roof on a structure or a
floor in a structure.
Embodiments of the present invention provide a
composite building panel that includes a central body,
substantially parallelepipedic in shape, containing an
expanded polymer matrix as described above, having
opposite faces, a top surface, and an opposing bottom
surface; at least one reinforcing embedded stud
longitudinally extending across the central body between
the opposite faces, having a first end embedded in the
expanded polymer matrix, a second end extending away from
the bottom surface of the central body, and one or more
expansion holes located in the embedded stud between the
first end of the embedded stud and the bottom surface of
the central body, where the central body contains a
polymer matrix that expands through the expansion holes;
and a concrete layer covers at least a portion of the top
surface and/or bottom surface.
A particular embodiment relates to a tilt up
insulated panel that is adapted for use as a wall or
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ceiling panel. As shown in FIGS. 18-21, one-sided wall
panel 340 includes a reinforced body 341 that includes
expanded polymer form 342 (central body) and embedded
metal members 344 and 346 (embedded reinforcing bars).
Expanded polymer form 342 can include openings 348 that
traverse all or part of the length of expanded polymer
form 342. The embedded metal members 344 and 346 have
embedded ends 352 and 356 respectively that are not in
contact with inner face 350 of expanded polymer form 342.
The embedded metal members 344 and 346 also have exposed
ends 358 and 360 respectively that extend from outer face
362 of expanded polymer form 342.
Expanded polymer form 342 can have a thickness,
measured as the distance from inner face 350 to outer
face 362 similar in dimensions to that described above
regarding expanded polymer body 12.
Exposed ends 358 and 360 extend at least 1, in some
cases at least 2, and in other cases at least 3 cm away
outer face 362 of expanded polymer form 342. Also,
Exposed ends 358 and 360 can extend up to 60, in some
cases up to 40, and in other cases up to 20 cm away from
outer face 362 of expanded polymer form 342. Exposed
ends 358 and 360 can extend any of the distances or can
range between any of the distances recited above from
outer face 362.
In an embodiment of the invention, embedded metal
members 344 and 346 have a cross-sectional shape that
includes embedding lengths 364 and 366, embedded ends 352
and 356, and exposed ends 358 and 360. The orientation
of embedded metal members 344 and 346 is referenced by
the direction of embedded ends 352 and 356. In a
particular embodiment of the invention, embedded ends 352
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and 356 are oriented away from each other. In this
embodiment, one-sided wall panel 340 is adapted so that
exposed ends 358 and 360 of embedded metal members 344
and 346 are imbedded in concrete 370 that is applied to
outer face 362.
The spacing between each of embedded metal members
344 and 346 can be as described regarding embedded metal
studs 14 and 16 in wall unit 10.
In an embodiment of the invention, one-sided wall
panel 340 includes expanded polymer body 342 (central
body), embedded metal members 344 and 346 (reinforcing
embedded bars), which include flanges 311, cornered ends
312, utility holes 346 located in an exposed portion of
embedded metal members 344 and 346, expansion holes 313
in an embedded portion of embedded metal members 344 and
346, and embedded ends 344 and 346, which do not touch
inner face 350.
In an embodiment of the invention, inner face 350
can have a corrugated surface 351, which can be molded in
or cut in, which enhances air flow between inner face 350
and any surface attached thereto.
Expansion holes 313 are useful in that as expanded
polymer body 342 is molded, the polymer matrix expands
through expansion holes 313 and the expanding polymer
fuses. This allows the polymer matrix to encase and hold
embedded metal members 344 and 346 by way of fusion in
the expanding polymer. In an embodiment of the
invention, expansion holes 313 can have a flanged and in
many cases a rolled flange surface to provided added
strength to the embedded metal members.
Openings 348 can have various cross-sectional
shapes, and similar spacing and cross-sectional area as
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described regarding openings 18 in expanded polymer body
12.
Reinforced body 341 has a finite length and has a
male terminal end 371 that includes forward edge 372 and
a receiving end 374, which includes recessed section 376,
which is adapted to receive forward edge 372. Typically,
lengths of one-sided wall panel 340 are interconnected by
inserting a forward edge 372 from a first one-sided wall
panel 340 into a recessed section 378 of a second one-
sided wall panel. In this manner, a larger wall or
ceiling section containing any number of one-sided wall
panels can be assembled and/or arrayed. The width of
one-sided wall panel 340, measured as the distance from
protruding edge 380 to trailing edge 374 can typically be
at least 20, in some cases at least 30, and in other
cases at least 35 cm and can be up to 150, in some cases
up to 135, and in other cases up to 125 cm. The width of
one-sided wall panel 340 can be any value or can range
between any of the values recited above.
Example of a one-sided wall panel 340 according to
the invention is shown in FIGS. 20 and 21, where four
embedded metal members 344 and 346 are used. Concrete is
poured, finished and set to form a concrete layer 370
that encases exposed ends 358 and 360 of embedded metal
members 344 and 346.
The embedded ends 350 and 356 of embedded metal
members 344 and 346 are available as attachment points
for a finish surface 375 such as wood, rigid plastics,
wood paneling, concrete panels, cement panels, drywall,
sheetrock, particle board, rigid plastic panels, or any
other suitable material having decorating and/or
structural functions or other construction substrates as
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shown in FIG. 20 and 21). The attachment is typically
accomplished through the use of screws, nails, adhesive
or other fasteners known in the art.
In an embodiment of the invention, one-sided wall
panel 340 is assembled on a flat surface and a first end
is lifted while a second end remains stationary resulting
in orienting one-sided wall panel 340 generally
perpendicular to the flat surface. This is often
referred to as "tilting a wall" in the art and in this
embodiment of the invention, one-sided wall panel 340 is
referred to as a "tilt-up wall."
In embodiments of the tilt-up walls described
herein, the exposed ends of the embedded metal members
can act as a chair for the proper placement of
reinforcing wire mesh and/or rebar or other reinforcing
rods to the center of a concrete layer, poured, finished
and set to encase the exposed ends.
In embodiments of the tilt-up walls described herein
shown in FIG. 21, the exposed ends 358 and 360 of the
embedded metal members 344 and 346 can act as a chair for
the proper placement of reinforcing wire mesh 371 and/or
rebar or other reinforcing rods to the center of a
concrete layer 370, poured, finished and set to encase
the exposed ends
Another particular embodiment provides a composite
building panel where a first concrete layer covers at
least a portion of the top surface and encases at least
one first end of an embedded stud and a second concrete
layer covers at least a portion of the bottom surface and
encases at least one second end of an embedded stud.
This particular embodiment of the invention can
provide a second tilt up insulated panel that is adapted
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for use as a wall or ceiling panel. As shown in FIGS.
22-25, two-sided wall panel 440 includes a reinforced
body 441 that includes expanded polymer form 442 (central
body) and embedded metal members 444 and 446 (embedded
reinforcing bars). Expanded polymer form 442 can include
openings 448 that traverse all or part of the length of
expanded polymer form 442. The embedded metal members
444 and 446 have a first exposed end 452 and second
exposed end 456 respectively that extend from first face
462 of expanded polymer form 442. The embedded metal
members 444 and 446 also have second exposed ends 458 and
460 respectively that extend from second face 450 of
expanded polymer form 442.
Expanded polymer form 442 can have a thickness,
measured as the distance from second face 450 to first
face 462 similar in dimensions to that described above
regarding expanded polymer body 12.
The exposed ends can extend at least 1, in some
cases at least 2, and in other cases at least 3 cm away
either face 450 or face 462 of expanded polymer form 442.
Also, The exposed ends can extend up to 60, in some cases
up to 40, and in other cases up to 20 cm away from either
face of expanded polymer form 442. The exposed ends can
extend any of the distances or can range between any of
the distances recited above from either face of expanded
polymer form 442.
In an embodiment of the invention, exposed ends 452,
456, 458, and 460 are imbedded in first concrete layer
469 and second concrete layer 470 that are applied to
faces 450 and 462.
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The spacing between each of embedded metal members
444 and 446 can be as described regarding embedded metal
studs 14 and 16 in wall unit 10.
In an embodiment of the invention, two-sided wall
panel 440 includes expanded polymer body 442 (central
body), embedded metal members 444 and 446 (reinforcing
embedded bars), with cornered ends 412, utility holes 446
located in an exposed portion of embedded metal members
444 and 446, and expansion holes 413 in an embedded
portion of embedded metal members 444 and 446.
Expansion holes 413 are useful in that as expanded
polymer body 442 is molded, the polymer matrix expands
through expansion holes 413 and the expanding polymer
fuses. This allows the polymer matrix to encase and hold
embedded metal members 444 and 446 by way of fusion in
the expanding polymer. In an embodiment of the
invention, expansion holes 413 can have a flanged and in
many cases a rolled flange surface to provided added
strength to the embedded metal members.
Openings 448 can have various cross-sectional
shapes, and similar spacing and cross-sectional area as
described regarding openings 18 in expanded polymer body
12.
Reinforced body 441 has a finite length and has a
male terminal end 471 that includes forward edge 472 and
a receiving end 476 which includes recessed section 478,
which is adapted to receive forward edge 472. Typically,
lengths of two-sided wall panel 440 are interconnected by
inserting a forward edge 472 from a first two-sided wall
panel 440 into a recessed section 478 of a second two-
sided wall panel. In this manner, a larger wall, floor,
roof or ceiling section containing any number of two-
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sided wall panels can be assembled and/or arrayed. The
width of one-sided wall panel 440, measured as the
distance from forward edge 472 to recessed section 478
can typically be at least 20, in some cases at least 30,
and in other cases at least 35 cm and can be up to 150,
in some cases up to 135, and in other cases up to 125 cm.
The width of two-sided wall panel 440 can be any value or
can range between any of the values recited above.
An example of a two-sided wall panel 440 according
to the invention is shown in FIG. 24, where four embedded
metal members 444 and 446 are used. Concrete is poured,
finished and set to form concrete layers 469 and 470 that
encases exposed ends 452, 456, 458, and 460 of the
embedded metal members.
Alternatively, as shown in FIG. 25, one or both of
exposed ends 452 and 456 and/or 458 and 460 are available
as attachment points for a finish surface 475 such as
wood, rigid plastics, wood paneling, concrete panels,
cement panels, drywall, sheetrock, particle board, rigid
plastic panels, or any other suitable material having
decorating and/or structural functions or other
construction substrates. The attachment is typically
accomplished through the use of screws, nails, adhesives
or other fasteners known in the art. In this embodiment,
the space 476 defined by the finished surface 475,
exposed ends 452 and 456 and the expanded polymer body
442 can be used to run utilities, insulation and anchors
for interior finishes as described above.
The present invention provides a method of
constructing a building that includes assembling any of
the above-described composite building panels on a
generally flat surface, and lifting a first end of the
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composite building panel while a second end remains
stationary resulting in orienting the building panel to
form a wall of the building.
In an embodiment of the invention, two-sided wall
panel 440 is assembled on a flat surface and a first end
.
is lifted while a second end remains stationary resulting
in orienting two-sided wall panel 440 generally
perpendicular to the flat surface. This is often
referred to as "tilting a wall" in the art and in this
embodiment of the invention, two-sided wall panel 440 is
referred to as a "tilt-up wall."
In embodiments of the tilt-up walls described herein
and shown in FIG. 25, the exposed ends 458 and 460 of the
embedded metal members 444 and 446 can act as a chair for
the proper placement of reinforcing wire mesh 471 and/or
rebar or other reinforcing rods to the center of a
concrete layer 470, poured, finished and set to encase
the exposed ends.
In an embodiment of the invention, when the exposed
ends of the one-sided wall panel and the two sided wall
panel are encased in concrete as described above, utility
holes 346 and 446 act as sites where the set and hardened
concrete fuses through the holes and thereby holds and
attaches to the embedded metal members. Additionally,
reinforcing rods can be placed through utility holes 346
and 446 connecting embedded metal members, thus further
strengthening the formed wall panel.
As used herein, the term "concrete" refers to a hard
strong building material made by mixing a cementitous
mixture with sufficient water to cause the cementitous
mixture to set and bind the entire mass as is known in ,
the art.
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In an embodiment of the invention, the concrete can be a so called "light
weight concrete" in which light weight aggregate is included with the
cementitous
mixture. Exemplary light weight concrete compositions that can be used in the
present invention are disclosed in U.S. Pat. Nos. 3,021,291, 3,214,393,
3,257,338,
3,272,765, 5,622,556, 5,725,652, 5,580,378, and 6,851,235, JP 9 071 449, WO 98
02 397, WO 00/61519, and WO 01/66485
The wall units, floor units, tilt up insulated panels and I-beam panels
described herein contain variations that are not meant as limitations. Any of
the
variations discussed in one embodiment can be used in another embodiment
without
limitation.
The embodiment of the invention shown in FIG. 14 shows an example of
using combinations of the composite panels described herein and combining
features of the various panels. This embodiment combines I-beam panel 140 and
floor panel 92 (shown as 92 and 92A). In this embodiment, receiving end 176 of
I-
beam panel 140 accepts forward edge 93 of floor panel 92 and recessed section
99
of floor panel 92A accepts forward edge 172 of I-beam panel 140 to provide
tongue
and groove connections to establish continuous floor system 141. In this
embodiment, circular ductwork 148 is installed along bottom surface 100 of
floor
panel 92 between embedded metal joists 94 and 96. In this embodiment, the
flooring
material is concrete layer 145, which covers top surface 102 of floor panels
92 and
92A and outer face 162 oft-beam panel 140. I-beam channel 182 extends from and
is open to outer face 162 and is filled with concrete and
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the thickness of concrete layer 145 is sufficient to
encase exposed ends 158 and 160 of I-beam panel 140. The
combination shown in this embodiment provides an
insulated concrete floor system where utilities can be
run under an insulation layer.
In an embodiment of the invention, a lath can be
attached to the exposed ends of the metal studs, metal
joists or metal members of the wall units, floor units,
and expanded polymer panels; i.e. construction elements,
of the invention. The lath is capable of supporting a
covering layer constituted by a suitable construction
material. The lath can include one or more portions
extending flush on opposite lateral sides of the
construction element, which can be embedded in and
anchored also to the concrete used for incorporating
and/or joining together one or more adjacent construction
elements.
The lath can support one or more covering layers and
is typically a stretched metallic lath including a rhomb-
shaped mesh having a length-to-height rhomb ratio of
about 2:1. The
rhomb length can vary between 20 and 60
mm, while the rhomb width can vary between 10 and 30 mm.
The stretched metallic lath can have a thickness of from
0.4 to 1.5 mm and, in some cases of from 0.4 to 1.0 mm.
The covering layers can include one or more coating
layers of plaster, stucco, cement as it is or,
optionally, reinforced with fibers of a suitable
material.
In an embodiment of the invention shown in FIG. 29,
outer surface 24 of expanded polymer body 12 can have any
desirable type of surface. In some instances, outer
surface 24 will be smooth, in other instances grooves can
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be cut or molded into outer surface 24, in other cases
outer surface 24 can have ridges along the surface to
facilitate air flow, and in particular cases, as shown in
FIG. 29, outer surface 24 can be adapted to accept
stucco. In order to facilitate the application of stucco
to outer surface 24, T-slots 1300 can be cut into or
molded into outer surface 24. Any suitable type of
stucco can be used, non-limiting examples including
natural material stucco or polymer based stucco. Thus,
by including T-slots 1300 in outer surface 24, a stucco-
ready panel surface is provided. More particularly, T-
slots 1300 provide a mechanical connection for stucco
adhesion and no secondary mesh is required. In a
particular embodiment of the invention, T-slots 1300
allow for the use of natural material stucco, as this
type of stucco is able to breathe and not trap moisture.
When stucco is not applied to outer surface 24, T-slots
1300 can be used as water condensation channels or for
other finishing techniques.
A particular advantage of the construction panels,
wall units, floor units, and expanded polymer panels
according to the invention is directed to fire protection
and safety. As described above, a portion of the
embedded framing studs or embedded floor joists are
exposed and can include a web of holes formed along their
length. By exposing a section of the web of holes in the
embedded framing studs or embedded floor joists, air flow
is encouraged and in a fire situation, cooling of the web
section of the embedded framing studs or embedded floor
joists takes place. This can be very important to
prolonging the failure time of a loaded wall section.
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Typically, in a fire test, an insulated metal stud will
fail before a non-insulated stud in the center web area.
Locating spanner bars, as described above, in the
exposed web section, the embedded framing studs or
embedded floor joists act as a heat sink, helping to
dissipate heat from the center web section of the
embedded framing studs or embedded floor joists as well
as adding to the structural properties of the wall.
The melting properties of the polymer matrix in a
fire situation further facilitates the cooling of the
embedded framing studs or embedded floor joists web
section by melting away from the web as the temperature
exceeds 200 F, allowing further air circulation and
cooling of the web.
The bottom track of the wall panel, as described
above, can be designed to act as a drip and
containment pan in a fire event. The bottom track area
is designed to contain the solids that melt when the
polymer matrix burns. The bottom track is adapted to hold
a volume at least equivalent to the volume of the
expanded polymer matrix in the expanded polymer body in
liquid or molten form. Each track section can be
designed to have a holding capacity of from at least 0.2
ft3, in some instances at least 0.25 ft3, in some cases at
least 0.3 ft3 and in other cases at least 0.4 ft3 and the
holding capacity can be up to 0.75 ft3, in some cases up
to 0.65 ft3 and in other cases up to 0.1 ft3 of liquid or
molten material. The containment volume in the bottom
track can be any value or range between any of the values
recited above. The holding capacity of the bottom track
is typically designed to contain the solids contained in
a typical 48" x 96" construction panel.
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In lager construction panels, for example those of
greater height, the exterior portion of the bottom track
can be slotted, allowing for the evacuation of melt
materials to the exterior of the building. This design
greatly diminishes the interior fire spread and improves
the safety of the interior environment of the structure
during initial fire spread and rescue operations.
Embodiments of the present invention provide a stay
in place insulating concrete forming system that is
continuous in nature with length being limited only by
transportation and handling limitations. The present
insulating concrete forming system includes two opposing
foamed plastic faces connected internally and spaced
apart by perforated structural metal members. The foamed
plastic faces and metal spacing members are aligned
within the form to properly position vertically and
horizontally concrete reinforcement steel, while allowing
for proper concrete flow and finish work attachments. The
molded in structural steel members act as internal
bracing keeping the forms straight and aligned during
concrete placement eliminating the need for most external
blocking.
Further, the present invention provides pre-formed
insulated concrete forms that include one or more
reinforcing structural elements or bars running
longitudinally, the end of which are at least partially
embedded in oppositely facing expanded polymer bodies.
The remainder of the reinforcing structural element(s),
the portion between the expanded polymer bodies, are at
least partially exposed. The portions of the ends that
are encapsulated in the expanded polymer matrix can
provide a thermal break from the external environment.
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The reinforcing structural elements can be flanged
lengthwise on either side to provide attachment points
for external objects to the panel. Perforations in the
reinforcing structural elements in the end portions which
are encapsulated in the expanded polymer matrix allow for
fusion of the expandable polymer particles
perpendicularly. Perforations in the exposed portion of
the reinforcing structural element provide attachment
points for lateral bracing and/or rebar and allow for
uniform concrete flow when concrete is poured into the
present insulated concrete form. A tongue and groove or
overlapping connection point design provides for panel
abutment while maintaining the integrity of the concrete
form. Longitudinal holes can run through the expanded
polymer matrix and can be variable in diameter and
location to provide areas for placement of utilities,
lightening the structure and channels for venting of
gasses. Panel manufacture is accomplished through the
use of a semi-continuous or continuous molding process
allowing for variable panel lengths.
The embedded studs used in the invention can be made
of any suitable material as described above. In a
particular embodiment of the invention, the embedded
studs are made of a light gauge metal.
The embedded studs can have a thickness as described
above. The thickness of the embedded studs will depend
on the intended use of the pre-formed building panel.
In an embodiment of the invention, the embedded
studs have holes or openings along their length to
facilitate fusion of the expanded plastic material and to
reduce any thermal bridging effects in the reinforcing
bars, studs, joists and/or members.
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In the present invention, the foamed plastic faces
can be molded from any suitable expandable plastic
material, as described above, on a molding machine
capable of inserting the metal members and forming two
opposing face panels while maintaining the composite
materials in their relative position in a continuous or
semi continuous process.
In a particular embodiment of the invention, the
expandable thermoplastic particles are expandable
polystyrene (EPS) particles. These particles can be in
the form of beads, granules, or other particles
convenient for the expansion and molding operations as
described above.
More particularly, the present insulated concrete
form includes a first body, substantially
parallelepipedic in shape, containing an expanded polymer
matrix, having opposite faces, a first surface, and an,
opposing second surface; a second body, substantially
parallelepipedic in shape, containing an expanded polymer
matrix, having opposite faces, a first surface, an
opposing second surface; and one or more embedded studs
longitudinally extending across the first body and the
second body between the first surfaces of each body,
having a first end embedded in the expanded polymer
matrix of the first body, and a second end embedded in
the expanded polymer matrix of the second body. One or
more expansion holes are provided in the portion of the
embedded stud embedded in the first body and the second
body. The first body and the second body include a
polymer matrix that expands through the expansion holes.
The space defined between the first surfaces of the first
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body and the second body is capable of accepting concrete
poured therein.
An embodiment of the present invention provides
insulated concrete forms (ICF) and ICF systems. As shown
in FIG. 30, ICF 510 includes first expanded polymer body
511 and second expanded polymer body 512, left facing
embedded metal studs 514, and right facing embedded metal
studs 516 (reinforcing embed bars). The embedded metal
studs 514 and 516 have embedded ends 520 and 522
respectively that do not touch outer surface 524 of first
expanded polymer body 511. Embedded metal studs 514
and 516 have embedded ends 521 and 523 respectively that
are adjacent to outer surface 525 of second expanded
polymer body 512. Space 505 is defined as the space
between inner surface 530 of first expanded polymer body
511 and inner surface 531 of second expanded polymer body
512 for the height of ICF 510.
Expanded polymer bodies 511 and 512 can have a
thickness, measured as the distance from inner surface
530 or 531 respectively to outer surface 524 or 525
respectively of at least 2, in some cases at least 2.5,
and in other cases at least 3 cm and can be up to 10, in
some cases up to 8, and in other cases up to 6 cm from
inner surface 30 of expanded polymer body 512. The
thickness of expanded polymer bodies 511 and 512 can
independently be any dimension or range between any of
the dimensions recited above.
Embedded ends 520 and 522 extend at least 1, in some
cases at least 2, and in other cases at least 3 cm into
expanded polymer body 512 away from inner surface 530.
Also, Embedded ends 520 and 522 can extend up to 10, in
some cases up to 8, and in other cases up to 6 cm away
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from inner surface 530 into first expanded polymer body
511. Embedded ends 526 and 528 can extend any of the
distances or can range between any of the distances
recited above from inner surface 530 into polymer body
511.
In another embodiment of the invention, embedded
ends 520 and 522 can extend from 1/10 to 9/10, in some
cases 1/3 to 2/3 and in other cases 1/4 to 3/4 of the
thickness of first expanded polymer body 511 into
expanded polymer body 511.
The orientation of embedded metal studs 514 and 516
is referenced by the direction of ends 520, 521, 522, and
523. The ends can be oriented in any direction that
suits the strength, attachment objectives or stability of
the insulated concrete form.
The spacing between each of embedded metal studs 514
and 516 is typically adapted to be consistent with local
construction codes or methods, but can be modified to
suit special needs. As such, the spacing between the
metal studs can be at least 10, in some instances at
least 25 and in some cases at least 30 cm and can be up
to 110, in some cases up to 100, in other cases up to 75,
and in some instances up to 60 cm. The spacing between
embedded metal studs 514 and 516 can be any distance or
range between any of the distances recited above.
ICF 510 can extend for a distance with alternating
embedded metal studs 514 and 516 placed therein. The
length of ICF 510 can be any length that allows for safe
handling and minimal damage to ICF 510. The length of
ICF 510 can typically be at least 1, in some cases at
least 1.5, and in other cases at least 2 m and can be up
to 25, in some cases up to 20, in other cases up to 15,
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in some instances up to 10 and in other instances up to 5
m. The length of ICF 510 can be any value or can range
between any of the values recited above. In some
embodiments of the invention, each end of ICF 510 is
terminated with an embedded metal stud.
The height of ICF 510 can be any height that allows
for safe handling, minimal damage, and can withstand the
pressure from concrete poured within ICF 510. The height
of ICF 510 can be at least 1 and in some cases at least
1.25 m and can be up to 3 M and in some cases up to 2.5
m. In some instances, in order to add stability to ICF
unit 510, reinforcing cross-members or rebar (not shown)
can be attached to embedded metal studs 514 and 516. The
height of ICF 10 can be any value or can range between
any of the values recited above.
Space 505, the space between inner surface 530 and
inner surface 531 for the height of ICF 510, can be any
suitable volume and/or dimensions. Suitable volume
and/or dimensions are those where the weight of concrete
poured into space 505 is no so high as to cause any part
of ICF 510 to fail, i.e., allow concrete to break through
ICF 510 such that the volume of concrete is not contained
in space 505, but large enough that the poured and set
concrete can support whatever is to be built on the
resulting ICF concrete wall. Thus, the distance between
inner surface 530 and inner surface 531 taken with the
height defined above can be at least 5 in some cases at
least 10 and in other cases at least 12 cm and can be up
to 180, in some cases up to 150 cm and in other cases up
to 120 cm. In some instances, in order to add stability
to ICF unit 510, reinforcing cross-members or rebar (not
shown) can be attached to embedded metal studs 514 and
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516. The distance between inner surface 530 and inner
surface 531 can be any value or can range between any of
the values recited above.
In a particular embodiment of the invention, ICF 510
can be used as a storm wall. In this embodiment, space
505 is filled with concrete as described herein and the
distance from inner surface 530 to inner surface 531 can
be at least 2 in some cases at least 5 and in other cases
at least 10 cm and can be up to 16, in some cases up to
14 cm and in other cases up to 12 cm. In this storm wall
embodiment, the distance between inner surface 530 and
inner surface 531 can be any value or can range between
any of the values recited above.
Storm walls made according to the present invention
can be used as any of the other wall panels and tilt-up
walls described herein.
As shown in FIG. 30, ICF 510 has a finite length and
first body 511 and second body 512 have an inner lip
terminus 517 and an outer lip terminus 518. Typically,
lengths of ICF 510 are interconnected by inserting an
inner lip terminus 517 of one ICF 510 adjacent an outer
lip terminus 518 of another ICF 510 to form a continuous
ICF. Thus, a larger ICF containing any number of ICF 510
units can be assembled and/or arrayed.
An alternative embodiment of the invention is shown
in FIG. 31, where ICF 508 is similar to ICF 510 except
that inner surface 530 of body 511 and inner surface 531
of body 512 include oppositely opposed inner arching
sections 532 and 534 respectively. Inner arching
sections 532 and 534 provide a non-linear space within
ICF 508, such that concrete poured into ICF 508 will have
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sections that have a larger cross-sectional width and
sections having a smaller cross-sectional width.
In another embodiment of the invention shown in FIG.
32, ICF 509 has exposed ends 536 and 538 instead of
embedded ends 521 and 523. Exposed ends 536 and 538
extend at least 1, in some cases at least 2, and in other
cases at least 3 cm away from outer surface 525 of second
expanded polymer body 512. Exposed ends 536 and 538 can
be used to attach finish surfaces, such as drywall,
plywood, paneling, etc. as described above to ICF 509.
Also, Exposed ends 536 and 538 can extend up to 60, in
some cases up to 40, and in other cases up to 20 cm away
from outer surface 525 of expanded polymer body 512.
Exposed ends 536 and 538 can extend any of the distances
or can range between any of the distances recited above
from outer surface 525.
Referring to FIG. 32, embedded metal studs 514 and
516 can have utility holes spaced along their length
between outer surface 525 and exposed ends 536 and 538.
The utility holes (not shown here, but as described and
illustrated above) are useful for accomodating utilities
such as wiring for electricity, telephone, cable
television, speakers, and other electronic devices, gas
lines and water lines. The utility holes can have
various cross-sectional shapes, non-limiting examples
being round, oval, elliptical, square, rectangular,
triangular, hexagonol or octagonal. The cross-sectional
area of the utility holes can also vary independently one
from another or they can be uniform. The cross-sectional
area of the utility holes is limited by the dimensions of
embedded metal studs 514 and 516, as the utility holes
will fit within their dimensions and not significantly
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detract from their structural integrity and strength.
The cross-sectional area of the utility holes can
independently be at least 1, in some cases at least 2,
and in other cases at least 5 cm2 and can be up to 30, in
some cases up to 25, in other cases up to 20 cm2. The
cross-sectional area of the utility holes can
independently be any value or range between any of the
values recited above.
In an embodiment of the invention, the utility holes
can have a flanged and in many cases a rolled flange
surface to provided added strength to the embedded metal
studs.
FIGS. 33 and 34 show features of the present ICF as
they relate to ICF 508 (FIG. 31). A feature of embedded
metal studs 514 and 516 is that they can include
expansion holes 540 and pour holes 542. As such pour
holes 544 can be a punched hole extending along the
vertical axis of embedded metal studs 514 and/or 516 that
is positioned to allow the free flow of normal concrete
and to fix and position horizontal concrete
reinforcements. Similarly, expansion holes 540 can be a
punched hole of sufficient diameter or slot of sufficient
void area to allow the fusion and flow of the polymer
matrix through the formed plastic panel.
The molded in light gauge metal structural members,
embedded metal studs 514 and 516, can be continuously or
semi continuously formed to create a composite panel of
unlimited length. The structural metal members are
strategically punched along the outer vertical axis to
provide expansion holes 540, which allow for the flow of
and fusion of the expandable plastic materials through
the metal members. The center vertical axis of the metal
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member is punched to provide pour holes 542, which permit
the free flow of normal concrete and to aid in the fixing
and placement of horizontal concrete reinforcement
materials. FIGS. 35 and 36 shows the formed and set
concrete 550 in relation to embedded metal studs 514 and
516.
Embedded ends 521 and 523 act as continuous furring
strips running vertically on predetermined centers to aid
in the direct connection of finish materials, top and
bottom structural tracks, wall penetrations and roof and
floor connection points, such as the level track
described herein.
The expandable plastic materials in the composite
panel acts as a forming panel when concrete is placed
within the form also provides insulation and sound
deadening. Further,
the expandable plastic materials
face of the composite panel acts as a forming panel when
concrete is placed within the form and also provides
insulation and sound deadening.
The design of the present ICF provides horizontal
and vertical concrete pathways created by the two
opposing face panels fixed by the light gauge structural
members.
When concrete is poured into space 505 of the
present ICF, an internal concrete post is formed by the
two opposing face panels within the vertical post wall
configuration of the panel design. The
concrete core
created in the form acts as horizontal bracing to the
light-gauge structural metal members in the present ICF.
In the vertical post wall panel design the concrete core
allows for horizontal reinforcement along the axis of the
vertical post created between the form face panels.
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In the present ICF, the interlocking panel ends
formed by inner lip 517 and outer lip 518 are self
aligning, self sealing and securely connect one panel
side termination to the other panel side termination
point, forming a continuous horizontal as well as
continuous vertical concrete placement form.
FIG. 37 shows an embodiment of the invention where
the surface of steel member 560, which can be used as
embedded metal studs 514 and/or 516 in the present ICF
are dimpled 565 in opposing directions creating a surface
that increases concrete adhesion and prevents cracking of
the concrete in contact with steel member 560. The dimple
effect on the member surface adds to the shear resistance
of the steel and concrete composition. The dimpling of
the steel surface creates a stronger connection between
the foam and the steel member of the plastic foam faces
of the panel when molded as a composite structure.
FIG. 38 shows an insulated concrete form system 575
for providing a foundation that includes a plurality of
ICF's 508 connected end to end to form ICF system 575.
Corner unit 552 is used to interconnect parallel ICF
lines 554 and perpendicular ICF lines 556. Concrete is
poured into space 505 of ICF wall system 575 and cured to
form a completed insulated concrete wall system.
Corner unit 552, as shown in FIG 39 essentially
includes a first ICF 508A and a second ICF 508B (like
features are numbered as above) oriented at an angle to
first ICF 508A, where corner section 562 is molded to
include first ICF 508A and second ICF 508B to form a
continuous first body and second body and providing a
continuous space 505 there between.
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Referring to FIG. 32, a particular advantages of ICF
509 includes the ability to easily run utilities prior to
attaching a finish surface to the exposed ends of the
embedded metal studs. The exposed metal studs facilitate
field structural framing changes and additions and leave
the structural portions of the assembly exposed for local
building officials to inspect the framing.
A utility space defined by outer surface 525 of
expanded polymer body 512 and exposed ends 536 and 538
can be adapted for accommodating utilities. Typically,
exposed ends 536 and 538 have a finish surface attached
to them, a side of which further defines the utility
space.
In an embodiment of the invention, the utility space
is adapted and dimensioned to receive standard and/or
pre-manufactured components, such as windows, doors and
medicine cabinets as well as customized cabinets and
shelving.
Further, the air space between the outer surface of
the expanded polymer body 512 and the finish surface
allows for improved air circulation, which can minimize
or prevent mildew. Additionally, because the metal studs
are not in direct contact with the outside environment,
thermal bridging via the highly conductive embedded metal
studs is avoided and insulation properties are improved.
The various embodiments described herein contain
variations that are not meant as limitations. Any of the
relevant variations discussed in the embodiments of ICF,
building, floor, ceiling, wall, and/or roof panels can be
used in the ICF, building, floor, ceiling, wall, and/or
roof panel embodiments described herein without
limitation.
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In an embodiment of the invention, a lath can be
attached to the exposed ends of the metal studs, metal
joists or metal members of the ICF of the invention. The
lath is capable of supporting a covering layer
constituted by a suitable construction material. The
lath can include one or more portions extending flush on
opposite lateral sides of the construction element, which
can be embedded in and anchored also to the concrete used
for incorporating and/or joining together one or more
adjacent construction elements.
The lath can support one or more covering layers and
is typically a stretched metallic lath including a rhomb-
shaped mesh having a length-to-height rhomb ratio of
about 2:1. The rhomb length can vary between 20 and 60
mm, while the rhomb width can vary between 10 and 30 mm.
The stretched metallic lath can have a thickness of from
0.4 to 1.5 mm and, in some cases of from 0.4 to 1.0 mm.
The covering layers can include one or more coating
layers of plaster, stucco, cement as it is or,
optionally, reinforced with fibers of a suitable
material.
In an embodiment of the invention, referring to
FIGS. 3 and 38, insulated concrete form system 575 is
foundation 130, where level track 128 is attached thereto
as described above. Further, the invention provides
buildings that include the present insulated concrete
form system as a foundation, with an optional level track
according to the invention attached thereto, and one or
more floor panels, floor systems, wall panels, wall
systems, tilt-up walls, storm panels, ceiling and/or roof
panels as described herein. In a particular embodiment of
the invention, the floor panels, floor systems, wall
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panels, wall systems, tilt-up walls and/or storm panels
can be attached to the insulated concrete form system,
optionally using the present level track. Further to
this particular embodiment, the present ceiling and/or
roof panels can be attached to one or more of the present
wall panels, wall systems, tilt-up walls and/or storm
panels. Thus a novel building is provided.
The ICF units of the present invention can be made
using an apparatus for molding a semi-continuous or
continuous foamed plastic element that includes
a first mold including:
i) a bottom wall, a pair of opposite side walls
and a cover, and
ii) a molding seat, having a shape mating that of
the element, defined in the mold between the side walls,
the bottom wall and the cover;
a second mold including:
i) a bottom wall, a pair of opposite side walls
and a cover, and
ii) a molding seat, having a shape mating that of
the element, defined in the mold between the side walls,
the bottom wall and the cover;
b) means for displacing the covers and the side
walls of the molds towards and away from the bottom wall
to longitudinally close and respectively open the mold;
and
c) first means for positioning in an adjustable
manner said covers away from and towards said bottom wall
of the mold to control in an adjustable and substantially
continuous manner the height of the molding seat.
The apparatus is configured to include the
reinforcing members, embedded metal bars, embedded metal
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studs, embedded metal joists, and embedded metal members configured as
discussed above. As a non-limiting example, the methods and apparatus
disclosed
in U.S. Pat. No. 5,792,481 can be adapted to make the ICF units, of the
present
invention.
The wall units, floor units, and expanded polymer panels of the present
invention can
be made using batch shape molding techniques. However, this approach can lead
to
inconsistencies and can be very time intensive and expensive.
In an embodiment of the invention, the wall units, ceiling units, roof units,
floor units,
and expanded polymer panels of the present invention can be made using an
apparatus for molding a semi-continuous or continuous foamed plastic element
that
includes
a) a mold including: i) a bottom wall, a pair of opposite side walls and a
cover, and ii)
a molding seat, having a shape mating that of the element, defined in the mold
between the side walls, the bottom wall and the cover;
b) means for displacing the cover and the side walls of the mold towards and
away
from the bottom wall to longitudinally close and respectively open the mold;
and
c) first means for positioning in an adjustable manner said cover away from
and
towards said bottom wall of the mold to control in an adjustable and
substantially
continuous manner the height of the molding seat.
The apparatus is configured to include the reinforcing members, embedded metal
bars, embedded metal studs, embedded metal joists, and embedded metal
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= =
studs, embedded metal joists, and embedded metal members configured as
discussed above. As a non-limiting example, the methods and apparatus
disclosed
in U.S. Pat. No. 5,792,481 can be adapted to make the wall units, floor units,
and
expanded polymer panels of the present invention.
In an embodiment of the invention, the reinforcing members, embedded metal
studs, embedded metal joists, and/or embedded metal members 220 can be molded
into the wall units, floor units, and expanded polymer panels having a formed
embedded end 222 and a straight exposed end 224 as shown in FIG. 26.
Subsequently, the straight exposed end can be formed, worked and/or modified
to
provide a shaped end 228A as shown in shaped member 226A in FIG. 27 or a
shaped end 228B as shown in shaped member 226B FIG. 28. Embedded ends 226A
and 226B can remain unchanged from embedded end 222. Equipment and
machinery for subsequently bending, working, forming or modifying the exposed
end
are well known in the art.
In an embodiment of the invention, the inner surface, bottom surface, or inner
face of the wall units, floor units, and expanded polymer panels described
above can
have a grooved surface, either molded in or applied mechanically to improve
air flow
through the annular space between the expanded plastic and any materials
attached
to the exposed ends of the metal studs, metal joists or metal members of the
wall
units, floor units and expanded polymer panels described above.
The present invention is directed to a method of constructing a building in a
first embodiment including:
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providing a foundation having a series of walls
having top surfaces, which can include the present
insulated concrete form system;
positioning and securing the composite building
panels described above, adapted for use as a floor unit,
and/ or floor panels or floor systems as described
herein, such that the floor unit, panel and/or system
spans at least a portion of the top surfaces of the
foundation walls;
positioning and securing any of the wall systems
described above to the floor unit or system; and
positioning and securing a roof system as described
above to a top surface of the wall system.
Another embodiment of the invention provides a
method of constructing a building that includes:
providing a foundation having a series of foundation
walls having top surfaces, which can include the present
insulated concrete form system;
positioning and securing the composite building
panels described above, adapted for use as a floor unit,
and/ or floor panels or floor systems as described
herein, such that the floor unit, panel and/or system
spans at least a portion of the top surfaces of the
foundation walls;
positioning and securing two or more of the
composite building panels and/or storm panels described
above, adapted for use as a wall unit, to at least part
of a top surface of the floor unit, wherein a bottom
track and a top slip track are attached to a bottom end
and a top end respectively of the composite building
panels; and
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positioning and securing the composite building
panels described above, adapted for use as a roof unit,
to at least some of the top slip track of the wall units.
Further to this embodiment, a method of constructing
a multi-story building is provides that further includes:
positioning and securing the composite building
panels described above, adapted for use as a second floor
unit or system, to at least a portion of the top slip
track of the wall units; and
positioning and securing two or more of the
composite building panels and/or storm panels described
above, adapted for use as a second wall unit, to at least
part of a top surface of the second floor unit, wherein a
bottom track and a top slip track are attached to a
bottom end and a top end respectively of the composite
building panels;
where the roof unit is secured to at least some of
the top slip track of the second wall units.
Thus, the present invention also provides a building
that contains one or more of the floor units, wall
systems and roof systems described above.
The wall units, floor units and expanded polymer
panels of the present invention provide a number of
advantages. For example, they typically eliminate the
need for house wrap. The expanded polymers used in the
present invention typically have at least an equivalent
rating as required by local building codes for house
wraps.
Also, no insulation subcontractors are required
during construction as the wall units, floor units and
expanded polymer panels of the invention already include
adequate insulation. The materials of construction also
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effectively blocks low frequency sound waves resulting
from exterior noise.
The acoustical properties of the construction
panels, wall units, floor units and expanded polymer
panels according to the invention are particularly
advantageous. Typically, metal studded structures have
major acoustical or sound transmission problems. The
metal studs will generally amplify sound through their
ability to vibrate. When the metal studs are
encapsulated in the polymer matrix, vibration is reduced,
which results in reduced vibration and desirable
acoustical and sound transmission properties.
Further, less framing is required on a job site
because of the prefabricated nature of the present wall
units, floor units and expanded polymer panels.
The generally faster construction time resulting
from using the present wall units, floor units and
expanded polymer panels allows for earlier enclosure and
protection from the elements leading to less water damage
during construction. Additionally, the provided holes,
openings, conduits, chases and spaces in the present wall
units, floor units and expanded polymer panels results in
faster wiring and plumbing and less job site scrap.
The present invention also relates to a method of
doing business that allows an architectural design layout
to be accessed by the apparatus for molding a semi-
continuous or continuous foamed plastic element in order
to customize the size, shape and dimensions of the
various elements of the construction panels, wall units,
floor units, and expanded polymer panels of the
invention. The architectural design layout can be
provided via software from a disk or via an Internet
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connection. For those customers with Internet
capabilities, access to the present method is convenient
and provides an efficient and time saving method to
design and manufacture building and/or housing units.
In a non-limiting exemplary embodiment, a customer
selects an architectural design for a building. The
architectural design includes the unique features of each
composite building panel to be used in the building. The
architectural design is loaded into a processing unit
that translates the design into instructions for the
apparatus for molding a semi-continuous or continuous
foamed plastic element. The instructions direct the
apparatus to continuously or semi-continuously mold
panels as described above and what customizing features
to include in each panel.
The architectural design can include, as non-
limiting examples the dimensions of and the location of
openings and holes required in each reinforcing embedded
stud as well as any indentations in each composite
building panel needed to build the building; the
dimensions of each composite building panel to include
thickness, width, height, spacing between embedded studs,
dimensions and shape for each embedded stud, any channels
that need to be cut into or formed in the central body of
each composite building panel, any of the design features
described above, any other unique features for each
composite building panel, as well as gable ends
accommodating any roof pitch or slope, bay window floor
cuts and other design specified architectural features.
The processing unit can be any computer or device
capable of reading instructions and translating them into
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instructions for the apparatus for molding a semi-
continuous or continuous foamed plastic element.
The customizing features can include any of the
architectural design features described above. As a non-
limiting example, the customizing features can include
forming a straight exposed end as shown in FIG. 26 to a
shaped end as shown in either of FIGS. 27 and 28.
In another embodiment of the invention, an
interactive computer program can be used to provide the
architectural designs described above. In an embodiment
of the invention, the architectural design can be
inputted using a series of computer screen menus, where a
user selects choices made available on a computer screen.
When the design button is selected, a screen appears for
additional choices for modifying the central body, the
embedded framing studs or embedded floor joists, and/or
the spatial relationship between the two. Selecting any
of the menus directs to another screen where specific
architectural design features as described above can be
inputted as well as the number of panels required that
have those features. Upon selection, additional
customized panels can be inputted. The user then
verifies the order by selecting an "order panels" button.
The instructions are then relayed to the apparatus for
molding a semi-continuous or continuous foamed plastic
element and each of the requested number of panels having
each of the architectural design features are molded and
cut to the order specifications. In an embodiment of the
invention, all panels are automatically labeled and
marked for placement in their proper position.
In a further embodiment, the customer requests
access to an interactive program that steps the customer
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through the design process. Once the design is complete,
the customer can save the design for future use. The
customer may also choose to submit the design for an
order.
The use of a design program on an Internet site
benefits the manufacturer in a variety of ways including
a method of gathering customer profiles that can later be
used for mailings, etc. In addition, an Internet site
that includes this unique method of doing business
reaches worldwide and generates name recognition for the
manufacturer, particularly where the construction panel
manufacturer is the is the only manufacturer to offer an
accessible and convenient method of designing and
ordering composite construction panels.
The design program of the invention provides an
advantage for the user in his or her own business in that
it raises the level of professionalism of the user by
allowing prompt and on-the-spot service for his or her
own customers. For example, a customer may bring a sketch
or layout for an architectural design a composite
construction panel shop requesting construction panels to
use in the layout or design. In response, the panel shop
owner, i.e., user, can utilize the design program to
build a series of composite construction panels on a
computer screen with the customer by his side, and
explain to the customer the benefits of the custom
composite construction panels. This process provides a
first rate service to the customer, eliminates guessing,
increases interaction between the panel shop and the end
customer, and enhances business reputation in the field.
FIG. 40 illustrates a method of doing business 400
between a composite construction panel manufacturer 420
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and a customer 414, 416 requiring the manufacture of
custom composite construction panels. A composite
construction panel design program is provided to a
customer 414, 416 via a hard copy 418, e.g., a disk
containing a copy of the program, or via electronic
access, e.g., the Internet or e-mail. The composite
construction panel design software is utilized by a
customer on the customer's personal computer 414, 416.
The customer designs one or more composite construction
panels and delivers the completed design to the
manufacturer 420. The design can be printed to provide a
hard copy 418 to the manufacturer 420. In a particular
embodiment of the present invention, the finished design
is uploaded to a central computer 406 located at the
manufacturer 420. In another particular embodiment,
compatibility between the design program software and the
software of the apparatus for molding a semi-continuous
or continuous foamed plastic element 408 allows the
finished design specifications to be entered into the
apparatus 408 directly through a connection to the
central computer. In another embodiment, the design
specifications are entered manually by an apparatus
operator. The design software stores and sorts the data
based on particular panel design types, and identifies
the most efficient sequence for making panels. Thus,
the software is usable as a management tool to simplify
the work of the apparatus operator, including specifying
what order to make the panels and how to maneuver parts
of the apparatus to change from one panel design to the
next. The method of doing business as illustrated in
FIG. 40 reduces the time and cost to design and
manufacture custom construction panels.
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The present invention has been described with
reference to specific details of particular embodiments
thereof. It is not intended that such details be
regarded as limitations upon the scope of the invention
except insofar as and to the extent that they are
included in the accompanying claims.
