PANNEAU A AME DE MOUSSE POUR BATIMENTS PREFABRIQUES

FOAM CORE PANEL FOR PREFABRICATED BUILDINGS

Abrégé anglais

The present invention relates to a building panel for forming walls, roofs and
floors in a
building constructed with a frame including an expanded foam plastic core
rectangular in
shape, circular voids extending through the thickness of said core, each of
the plurality of
circular voids spaced apart to receive tension members, a coating applied to
at least one face
providing added rigidity and a frame comprising elongated members having
channels sized
to fit on the end faces of the panels for joining a pair of said building
panels together.

Revendications

What we claim is:
1. A building panel for forming walls and roofs in a building constructed with
a frame
having channel members said panel comprising:
an expanded foam plastic core having first and second major faces and end
faces each
said end face being adapted to be received in a channel member, said core also
including
spaced horizontally extending parallel bores to receive tension members and a
coating on
at least one said face for providing added rigidity, said frame having
recessed channels
of a width to fit adjacent building panels for joining adjacent building
panels together.
2. A panel for walls and roofs as claimed in claim 1, wherein said coating on
said
building panel is plywood.
3. A panel as claimed in claim 1 wherein said building panel expanded plastic
core is
made of styrene.
4. A panel as claimed in claim 1 wherein said building panel plastic foam core
is made
of styrene.
5. A panel as claimed in claim 1 wherein said channel members intermediate
ends of the
building are I beams. and channel members at the ends have U shaped cross
section.
6. A panel as claimed in claim 1 wherein said coating on said panel is
corrugated plastic
board.

Description

CA 02643945 2008-11-13
FOAM CORE PANEL AND STUCTURAL MEMBERS
FOR PREFABRICATED BUILDINGS
Field of the Invention
This invention relates to a prefabricated building assembly for low-cost
construction of walls,
roofs, and floors that includes the use of a plurality of prefabricated
building modules made of
panels having a foam plastic core of the desired thickness, with the side
edges of the building
panel having prefabricated channels that engage connectors for joining the
panels together to
form walls, roofs, and floors. Each panel also includes a polymer coating,
corrugated plastic or
wood sheeting on its outsides to provide a finish, structural strength, and
rigidity. Each panel also
includes a plurality of circular bores or voids that extend all the way
through the thickness of the
panel across the width of each panel from side to side, each of the passages
being parallel and
spaced at a predetermined and equal distance apart to accommodate partially
threaded horizontal
steel rods or cables which fasten the modules together to provide rigidity for
the structure.
The modules may be used to construct walls of various sizes provided that the
dimensions of the
channel members vary accordingly. Flange type connectors are inserted at the
bottom of each
channel members to secure the wall units to the floor by fastening means such
as screws. The
channels may be made of plastic or metal.
Plywood or cement floors or foundations are also possible with system. The
building system
may be used vertically for traditional or arch-type buildings and for dome-
type structures. The
exterior of the modules is preferably covered with a waterproof fabric such
vinyl.
Background of the Invention
U.S. Pat. No. 4,194,919 to Hattori, et al., describes a method for increasing
flexural strength of
cement compositions. The flexural strength of hydraulic cement compositions
are increased by
water-soluble epoxy resins.

CA 02643945 2008-11-13
U.S. Pat. No. 5,921,046 to Hammond, et al., provides a plastic foam core for
epoxy cement
concrete. There is no description or discussion to provide a foam core with a
coating of epoxy
resin and plastic pipe as described in Applicant's invention herein.
None of the references cited herein disclose Applicant's building block having
a foam core with
an integral vertical plastic or metal channel members nor provide a low-cost
lightweight
construction block that includes preformed voids for horizontal steel rods and
a low-cost
permanent coating that prevents lateral buckling.
Summary of the Invention
A prefabricated building assembly for constructing walls, roofs, and floors,
comprising a
prefabricated building panel made up of substantially a foam plastic core..
Each of the building
panels has horizontal spaced circular voids to receive threaded steel rods or
cables .
The side face of the building panel is received in a channel member. The
purpose of these
channel members is to provide connection between adjacent panels when joined
together, such
that a channel member disposed there between provides alignment and connection
of adjacent
panels.
The building panel includes an epoxy or acrylic resin coating, corrugated
plastic board or
plywood on its side walls to provide strength and a finished surface on the
plastic foam core of
the building panel. The connector system, which includes a plurality of
elongated channel
members, which are also made of plastic or metal The basic foam panel is also
coated with the
epoxy or acrylic resin. The coating is also used as adhesive along the
connectors and wall
interface.
The building panel also includes a plurality of small passageways, both
horizontally and
vertically disposed, for electrical wiring, the passageways being
approximately 3/4 in. in
diameter.
2

CA 02643945 2008-11-13
The building assembly may be used to construct walls, roofs, and floors. The
building assembly
system described herein can also be used to form roof connections and a
building roof with
supporting trusses.
One of the purposes of the building assembly in the present invention is the
use of styrene or
urethane foam blocks for the construction, that it can be prefabricated in a
factory environment
and then shipped to the building site, so that less manual labor or finishing
is required. The
building assembly in accordance with the present invention has impact and
compressive load
strength. When using the present building assembly, the time of construction
is greatly reduced.
The building panels and assembly connectors are prefabricated in a factory and
come in a
finished condition.
After the footer and slab have been poured, a building panel in accordance
with the present
invention will be placed on top of flange connectors that are secured to the
slab by screws. A
roof type second building panel will be mounted on top of the first building
panel and will
include cylindrical connectors. Again, the epoxy or acrylic resin coating can
be used for adhering
the cylindrical connectors to the recessed walls of each of the building
blocks, apart in the
building panels, with the channel members progressing vertically up to the top
of the wall. The
same construction technique can be used on roofs, as described in greater
detail below.
The present invention seeks to provide a building panel for forming walls,
roofs and floors in a
building constructed with a frame substantially rectangular in shape, first
and second faces
defined by the ends of said core, the end faces each being rectangular, said
core also including a
plurality of circular voids extending through the thickness of said core
between said first and
second face, each of said plurality of said circular voids being essentially
parallel and each of
said circular voids being spaced apart to receive tension members, a plastic
resin forming a
coating, integrally applied to at least said first face, said coating being
approximately one quarter
inch thick for added rigidity; and the frame comprising rectangular, elongated
members, sized
in radius to fit over said panels s for joining a pair of said building panels
together.
3

CA 02643945 2008-11-13
Thc present invention also seeks to provide a panel, whcrein the building
panel foam expanded
plastic core is made of styrene or acr-Vlic. the building panel plastic foam
core is made of uretl-iane
and Nvherein the fi-ame members is made of'plastic.
Brief 1_)escription of the Drawings
F1G. I is a perspective view of wall atid roof panels in accordance with this
invention
FIG. ? is a perspective view of side by side panels. and
FIG. 3 is a perspective view of an assembled bi.lildin` struclure
I)escri .ption of the Preferred I_lmbodiment
'T11e building assemblv in accordance tivith the present invention uses
prefabi-icated modules.
'T'he.se modules or panels 10 c.ornprise rigid toam plastic that has wood
sheeting I I provided
with adhesive on both interior and exterior sides ofpanels to ensure its
rigiditv as shown in FIG.3.
Both vertical sides 18 of panels 10 are adapted to be reeeived in ver-tical
channels 12 of fi=ame
members 14. Fach building panel is provided Nvith lzorizontal holes or voids
(5/16 in.) 20, in
order to itlsert partially' threaded, 24 in. long, reintorcing steel rods 15
spaced every 2) ft., as
shown in FIG. 1.2 and 3. A ,vasher 26 and bolt connector 28 is placed oti
reinforcing steel rods
15 as shown in FIG. I and 2. Steel connectors 16 are used to join the
horizontal reinforcing steel
rods 15 to the frame members 14 after each panel 10 is in place to secure the
panels 10 together
in order to form one unit as shown in FIG. 1. . Plastic or nletal angled
connectors 30, 30a with
set screws 39 are. uscd, to,join sicle wall panels to roof panels as shown in
F1G. 1. In addition.
the wall panels have a predetermined angle at the top 15, the roof panels have
a pre-detertnined
angle 15 the top 13a and bottom 13b, in order for both panels (vvall and roof
or both roof-panels)
to joirl to c.reate a 45 degree angle, as shown in FIG. 1. zN metal anchor
connector 36 is used,
with set screws 38, at bottom of each ti-ame member 14 on either side of
panels 10 to secure them
to the foundation with 3 or 4 lag scretivs 36 at predrilled holes on steel
plate ofconnector,
whether it is wood or concrete as shown in F1G. 2 or 3 1'tle building unit is
covered with a
waterproof, fire retardant and U.V. protected vinyl membrane 2-2 which has a
horizontal loop
32) placed at the bottom of each side, to inset-t a horizontal plastic or
metal
4

CA 02643945 2008-11-13
pipe 34, as shown in FIG. 3. It is fastened with lag screws 36 spaced every
foot of the
foundation or floor, whether it is concrete or wood as shown in FIG. 3. It is
important to note
that all dimensions of materials are subject to change depending on the size
of building required.

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