U.S. patent application number 10/761971 was filed with the patent office on 2004-07-22 for eps foam modular construction system and method.
Invention is credited to Hambright, Gary W..
Application Number | 20040139680 10/761971 |
Document ID | / |
Family ID | 32719220 |
Filed Date | 2004-07-22 |
United States Patent
Application |
20040139680 |
Kind Code |
A1 |
Hambright, Gary W. |
July 22, 2004 |
EPS foam modular construction system and method
Abstract
A modular foam construction system utilizes polystyrene
materials and consists of a set of building panels, of
predetermined shape, which are configured to define a structure
when the panels are arranged and aligned together in accord with a
plan or set of instructions. Panels are locked together by coupling
together a set of predefined interlock slots, formed into each
panel at particular locations, with a set of corresponding
interlock keys configured for friction fit insertion into the
juxtaposed interlock slots. The keys are oversized to promote a
binding surface friction fit between slot and key and both keys and
slots are formed with angled sides to promote a pulling force
directed towards the bottom of a slot to promote and increase a
surface friction fit between slot and key along the slot bottom
surface.
Inventors: |
Hambright, Gary W.;
(Whittier, CA) |
Correspondence
Address: |
John W. Eldredge
Myers Dawes Andras & Sherman LLP
Suite 1150
19900 MacArthur Blvd.
Irvine
CA
92612
US
|
Family ID: |
32719220 |
Appl. No.: |
10/761971 |
Filed: |
January 20, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60441035 |
Jan 18, 2003 |
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60452025 |
Mar 5, 2003 |
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Current U.S.
Class: |
52/578 ;
52/582.1 |
Current CPC
Class: |
E04B 2002/0252 20130101;
E04B 1/6137 20130101; E04B 2/06 20130101; E04B 1/6158 20130101;
E04B 2002/0263 20130101; E04B 2002/0232 20130101; E04B 2001/0092
20130101; E04B 2001/6195 20130101 |
Class at
Publication: |
052/578 ;
052/582.1 |
International
Class: |
E04C 003/00; E04C
003/30; E04B 002/00 |
Claims
1. A modular system for constructing substantially rigid structures
from polystyrene materials comprising: a set of building panels, of
predetermined shape, the panels configured to define a structure
when the panels are arranged and aligned together in accord with an
instruction; a plurality of predefined interlock slots formed into
each panel and disposed at panel locations at which panels are to
be aligned in order to define a structure, an interlock slot of a
first panel being juxtaposed, in face-to-face manner, with an
interlock slot of a second panel when the panels are arranged and
aligned together in accord with the instruction; a plurality of
interlock keys, configured for friction fit insertion into the
juxtaposed interlock slots, the interlock keys spanning the
interlock slots of two panels so as to further align the panels and
substantially lock said panels together at the key/slot joint; and
wherein the building panels, interlock slots and interlock keys are
formed from polystyrene foam material so as to define a structure
with use of adhesives or conventional fasteners.
2. The modular construction system according to claim 1, wherein
interlock slots are formed as female-type, dove-tail slots having
predefined lateral dimensions.
3. The modular construction system according to claim 2, wherein
interlock keys are formed as male-type dove-tail, members having
predefined lateral dimensions oversized from the predefined lateral
dimensions of the interlock slots.
4. The modular construction system according to claim 3, wherein
the predefined lateral dimensions of the slots and keys comprise
the spacing between opposing angled sidewalls.
5. The modular construction system according to claim 4, wherein
the spacing between opposing angled sidewalls of an interlock key
is oversized to the spacing between opposing angled sidewalls of an
interlock slot by an amount ranging from about 0.005 inches to
about 0.007 inches.
6. The modular construction system according to claim 5, wherein
two building panels are joined together at abutting edges by an
interlock key having two adjoining joint members, disposed in
opposing relationship, each joint member insertable in a respective
panel's interlock slot, so as to lock the panels together in an
edge-to-edge relationship.
7. The modular construction system according to claim 5, wherein
two building panels are joined together along contiguous faces by
an interlock key defining a single joint member, the joint member
insertable in a respective panel's interlock slot and spanning a
contiguous slot defined by adjoining panels, so as to lock the
panels together along their faces.
8. The modular construction system according to claim 5, wherein an
interlock key comprises a multiplicity of joint members, disposed
at angles with respect to one another such that panels are joined
together in accord with the angles of the joint members.
9. In a modular construction system, a method for fitting together
building elements formed from polystyrene foam in a manner
providing structural rigidity sufficient for light duty structures
or enclosures, the method comprising: defining a set of building
panels, of predetermined shape, the panels configured to define a
structure when the panels are arranged and aligned together;
forming a plurality of predefined interlock slots into each panel
at particular panel locations at which panels are to be joined
together in order to define a structure; aligning at least a first
and second panel together so as to juxtapose respective interlock
slots with one another; and spanning the juxtaposed interlock slots
of two panels with at least one interlock key, the key configured
for friction fit insertion into the juxtaposed interlock slots, the
interlock key further aligning the panels and substantially locking
said panels together at the key/slot joint.
10. The method according to claim 9, wherein two building panels
are joined together at abutting edges by an interlock key having
two adjoining joint members, disposed in a "butterfly"
relationship, each joint member insertable in a respective panel's
interlock slot, so as to lock the panels together in an
edge-to-edge relationship.
11. The method according to claim 9, wherein two building panels
are joined together along contiguous faces by an interlock key
defining a single joint member, the joint member insertable in each
respective panel's interlock slot and spanning a contiguous slot
defined by adjoining panels, so as to lock the panels together
along their faces.
12. The method according to claim 9, wherein an interlock slot
further comprises a trapezoidal channel having a floor or bottom,
an opening or throat and two opposing angled sides such that the
width dimension of the channel floor is larger than the width
dimension of the channel throat.
13. The method according to claim 12, wherein an interlock key
comprises a trapezoidal member having a shape conforming to the
shape of the channel, and wherein the interlock key has width
dimensions at its respective angled sides oversized from the width
dimensions of a respective slot's angled sides, such that insertion
of a key into a corresponding slot defines a surface friction force
at adjoining angled side surface interfaces.
14. The method according to claim 13, wherein the angled sides of
the interlock slots and keys cooperate to define a locking force
along the length of adjoining angled sides as the key is inserted
into a corresponding slot, the locking force directed towards an
interlock channel floor, thereby exerting a pulling force on an
interlock key and encouraging a further frictional fit bond between
a slot and a key along the channel floor.
15. The method according to claim 14, wherein two building panels
are joined together at abutting edges by an interlock key having
two opposed joint members, configured in a "butterfly"
relationship, each joint member insertable in a respective panel's
interlock slot, so as to lock the panels together in an
edge-to-edge relationship.
16. A modular building system for constructing substantially rigid
structures from polystyrene elements without use of adhesives or
fasteners, the system comprising: a set of building panel
components, the panel components sized and shaped to define a
structure when arranged and aligned together, horizontally and
vertically; a plurality of interlock joints of a first type formed
into each panel and disposed at panel locations at which particular
panels are to be joined together in order to define a structure;
and a plurality of interlock joints of a second type, configured
for friction fit insertion with respect to the interlock joints of
the first type, the first and second interlock joint types
cooperating to substantially lock said panels together at the
joint.
17. The building system according to claim 16, wherein the
interlock joints of a first type comprise a regular trapezoidal
channel including a floor having a first width, a throat opening
having a second, smaller, width, and two angled sides.
18. The building system according to claim 17, wherein the
interlock joints of a second type comprise a regular trapezoidal
member configured for insertion into the regular trapezoidal
channel, the member including a side corresponding to the channel
floor having a first width, a side corresponding to the channel
throat opening having a second, smaller, width, and two angled
sides, the widths of the trapezoidal member being larger than the
corresponding widths of the trapezoidal channel by from about 0.005
inches to about 0.007 inches.
19. The building system according to claim 18, wherein insertion of
a key into a corresponding slot defines a surface friction force at
adjoining angled side surface interfaces.
20. The building system according to claim 19, wherein the angled
sides of the interlock slots and keys cooperate to define a locking
force along the length of adjoining angled sides as the key is
inserted into a corresponding slot, the locking force directed
towards an interlock channel floor, thereby exerting a pulling
force on an interlock key and encouraging a further frictional fit
bond between a slot and a key along the channel floor.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is related to and takes priority
from U.S. Provisional Patent Applications Serial Nos. 60/441,035,
filed Jan. 18, 2003 and 60/452,025, filed Mar. 5, 2003, the entire
contents of which are expressly incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention is related to modular EPS foam
building materials and, more particularly, to standardized foam
building blocks assembled for rigid single piece performance
without using tools or adhesives.
BACKGROUND OF THE INVENTION
[0003] Modular building panels have a rather broad utility in the
construction industry and are used to form a number of
prefabricated structures, such as sheds, warehouses, and the like.
However, there are a number of structures that do not require
fabrication from conventional materials. These structures are
generally erected outdoors and are not required to conform to
construction building codes.
[0004] In particular, such structures may comprise a child's
playhouse, for example, a basis for a decorative exterior wall or
fence, a tool storage shed, pool house, or even a non-code living
enclosure such as a gazebo, breezeway, or porch enclosure or
sunroom.
[0005] Fabricating these structures from conventional materials
such as metal or wood framing and plywood facing is costly and
typically requires the services of experienced construction
contractors. The materials used in these construction projects are
bulky and rather heavy, making them difficult to purchase and
transport in a normal consumer's vehicle and are further relatively
unwieldy for a casual consumer to manipulate.
[0006] Although foam materials have been frequently incorporated
into various construction techniques, foam has not been previously
used for structural aspects of a structure. Foam materials have
been used to define alignment tools for cinderblock structures, for
example, but have not been used in place of the cinderblocks
themselves.
[0007] Since many structures are not required to conform to
building code requirements, it would be useful if foam materials
could be incorporated into the structural and load bearing aspects
of such structures in place of the more bulky conventional
materials. In order to have such structures be easily designed and
assembled, foam structural materials should be provided in
standardized shapes and sizes, such that they need only be
assembled in accordance with simple printed instructions and
affixed together utilizing a standardized interlock member.
[0008] Given such a standardized shape and size, such foam
materials can be combined together in order to form structures in a
manner similar to the well known LEGGO.TM. building block
system.
[0009] Thus, it will be seen that there is a need for a simple,
inexpensive and lightweight construction element set that can be
assembled into a structure without the use of adhesives or
fasteners but nevertheless provide a rigid and structurally sound
final product. Because the pieces are generally standardized, a
structure of any size or shape may be implemented from standard
pieces by merely adding or deleting a course from the length or
height of a particular structural dimension. Such a system should
also incorporate non-linear construction elements, such as rounded
corner panels, angled abutments, and the like.
SUMMARY OF THE INVENTION
[0010] Such a modular foam construction system is described below.
In a first aspect, the invention is characterized in terms of a
modular system for constructing substantially rigid structures from
polystyrene materials and suitably comprises a set of building
panels, of predetermined shape, which are configured to define a
structure when the panels are arranged and aligned together in
accord with a plan or set of instructions.
[0011] a plurality of predefined interlock slots is formed into
each panel and disposed at panel locations at which panels are to
be aligned in order to define a structure. For example, an
interlock slot of an edge portion of a first panel is juxtaposed,
in face-to-face manner, with an interlock slot of an edge portion
of a second panel when the panels are arranged and aligned
together. A plurality of interlock keys are configured for friction
fit insertion into the juxtaposed interlock slots. An interlock key
spans the interlock slots of two panels so as to further align the
panels and substantially locks the panels together at the key/slot
joint. Specifically, the building panels, interlock slots and
interlock keys are formed from EPS polystyrene foam material and
are affixed together in order to define a structure without use of
adhesives or conventional fasteners.
[0012] In a further aspect of the invention, interlock slots are
formed as female-type, dove-tail slots having predefined lateral
dimensions, and interlock keys are formed as male-type dove-tail,
members having predefined lateral dimensions oversized from the
predefined lateral dimensions of the interlock slots. Specifically,
the predefined lateral dimensions of the slots and keys comprise
the spacing between opposing angled sidewalls. The spacing between
opposing angled sidewalls of an interlock key is oversized to the
spacing between opposing angled sidewalls of an interlock slot by
an amount ranging from about 0.005 inches to about 0.007
inches.
[0013] One of the advantageous features of the invention is the
ability to join panels together along abutting edges and along
contiguous faces. Two building panels are joined together at
abutting edges by an interlock key having two adjoining joint
members, disposed in opposing relationship, each joint member
insertable in a respective panel's interlock slot, so as to lock
the panels together in an edge-to-edge relationship. Two building
panels are joined together along contiguous faces by an interlock
key defining a single joint member, the joint member insertable in
a respective panel's interlock slot and spanning a contiguous slot
defined by adjoining panels, so as to lock the panels together
along their faces.
[0014] In a further feature, an interlock key comprises a
multiplicity of joint members, disposed at angles with respect to
one another such that panels are joined together in accord with the
angles of the joint members in order to form structures having
other than right angles at particular joints.
[0015] A method for fitting together building elements formed from
polystyrene foam in a manner providing structural rigidity
sufficient for light duty structures or enclosures comprises
defining a set of building panels, of predetermined shape, the
panels configured to define a structure when the panels are
arranged and aligned together and forming a plurality of predefined
interlock slots into each panel at particular panel locations at
which panels are to be joined together in order to define a
structure.
[0016] At least a first and second panel are aligned together so as
to juxtapose respective interlock slots with one another and the
juxtaposed interlock slots of two panels are spanned with at least
one interlock key, the key configured for friction fit insertion
into the juxtaposed interlock slots, the interlock key further
aligning the panels and substantially locking said panels together
at the key/slot joint. An interlock slot comprises a trapezoidal
channel having a floor or bottom, an opening or throat and two
opposing angled sides such that the width dimension of the channel
floor is larger than the width dimension of the channel throat. An
interlock key comprises a trapezoidal member having a shape
conforming to the shape of the channel, and wherein the interlock
key has width dimensions at its respective angled sides oversized
from the width dimensions of a respective slot's angled sides, such
that insertion of a key into a corresponding slot defines a surface
friction force at adjoining angled side surface interfaces.
[0017] Advantageously, insertion of a key into a corresponding slot
defines a surface friction force at adjoining angled side surface
interfaces thereby keeping two joined panels in relatively rigid
alignment. The angled sides of the interlock slots and keys
cooperate to define a locking force along the length of adjoining
angled sides as the key is inserted into a corresponding slot, the
locking force directed towards an interlock channel floor, thereby
exerting a pulling force on an interlock key and encouraging a
further frictional fit bond between a slot and a key along the
channel floor.
DESCRIPTION OF THE DRAWINGS
[0018] These and other features, aspects and advantages of the
present invention will be more completely understood when
considered in connection with the following specification, appended
claims and accompanying drawings, wherein:
[0019] FIG. 1a is a plan view of an exemplary standard building
panel, constructed in accordance with the practice of the present
invention;
[0020] FIG. 1b is a top view of the exemplary building panel of
FIG. 1a;
[0021] FIG. 1c is an end view of the exemplary building panel of
FIG. 1a;
[0022] FIG. 2a is a semi-schematic cross-sectional view of a dual
interlock key and two building panels incorporating interlock
slots;
[0023] FIG. 2b is semi-schematic cross-sectional view of a single
sided interlock key in accordance with the invention;
[0024] FIG. 2c is a semi-schematic cross-sectional view of two
building panels joined and locked together by an interlock key;
[0025] FIG. 3a is a cross-sectional view of two building panels and
an additional embodiment of an interlock member in accordance with
the invention;
[0026] FIG. 3b is a cross-sectional view of two building panels
joined together by the interlock member of FIG. 2a;
[0027] FIG. 4a is a cross-sectional view of an additional
embodiment of an interlock member for joining angled panels;
[0028] FIG. 4b is a cross-sectional view of multiple building
panels joined at angles to one another by the interlock member of
FIG. 4a;
[0029] FIG. 5a is a top view of a wall structure constructed in
accordance with principals of the invention;
[0030] FIG. 5b is a front plan view of the wall of FIG. 5a;
[0031] FIG. 5c is an end view of the wall of FIG. 5a;
[0032] FIG. 6a is a top plan view of the initial construction stage
of a hexagonal structure utilizing principals of the present
invention;
[0033] FIG. 6b is a semi-perspective view of the structure of FIG.
6a;
[0034] FIG. 7a is a plan view of a next stage of construction of a
hexagonal structure;
[0035] FIG. 7b is a semi-perspective view of the structure of FIG.
7a;
[0036] FIG. 8a is a top view of a third stage of construction of a
hexagonal structure;
[0037] FIG. 8b is a semi-perspective view of the structure of FIG.
8a;
[0038] FIG. 9a is a top view of a fourth stage in the construction
of a hexagonal structure; and
[0039] FIG. 9b is a semi-perspective view of a completed hexagonal
structure constructed in accordance with principal to the present
invention.
DESCRIPTION OF THE INVENTION
[0040] Briefly, the invention is characterized as a set of modular
building components that fit together in order to form "constructs"
for other structures, in a manner similar to the well known
LEGGO.TM. building block system. In the context of the
specification, a "construct" may be any structure or structural
portion that is comprised of multiple pieces that are affixed
together. For example, a storage shed is considered a "construct"
in that it is comprised, in its simplest form, of four walls, a
roof (flat or peaked), a door and perhaps other elements such as a
window, dormer, or the like.
[0041] The system of the present invention comprises a number of
standardized pieces utilizing molded or custom cut expanded
polystyrene (EPS) foam shapes having standardized sizes and
particular densities for the particular "construct" desired. The
standardized pieces are fit together utilizing an "interlock slot
and key" system which, while superficially similar to a dove-tail
joint utilized in woodworking, is particularly sized and shaped to
provide structural rigidity to coupled blocks.
[0042] While the building blocks of the present invention are
characterized as standardized in size and shape, this is more for
the sake of ease of description than a limitation on the practice
of the invention. Indeed, the building blocks (also termed building
panels, or simply panels) of the present invention may be provided
in a set of universal sizes, for creative building purposes, or
might be provided in custom or unique shapes for specific building
projects. Particularly, the use of EPS foam allows for the building
blocks to be simply and easily cut, whether by wire, hot wire,
laser, or router, into any desired shape and having any desired
surface texture. Specifically, the type of EPS foam contemplated
for use with the present invention is Type-IX expanded polystyrene
having a nominal density of 2.0 pounds per cubic foot
(lb/ft.sup.3). This is also commonly known as 2 pound foam to those
having skill in the art.
[0043] Common 2 pound foam exhibits a compressive strength of 25.0
psi at 10% deflection and a flexural strength of 50.0 psi. EPS foam
is inert, highly stable, contains no formaldehyde and is not
manufactured with CFCs. EPS foam is particularly suitable for
construction applications since it is extremely light in weight,
versatile, sanitary, energy efficient and most of all cost
effective.
[0044] Turning now to FIGS. 1a, 1b, and 1c, there is depicted in
plan, top and side view, respectively, a standard building block or
panel 10 constructed of EPS foam, in accordance with the present
invention. It can be seen from the exemplary embodiment of FIG. 1a
that the standardized building panel 10 is formed from a generally
rectangular slab of 2 pound EPS foam. The panel 10 is provided in a
number of configurations, 24 inch lengths, 36 inch lengths, 48 inch
lengths, and the like, and correspondingly graded heights, in order
to define a set of uniformly increasing panel sizes. Depending on
the "construct" desired to be built, each of the blocks or panels
10 are provided in standard thicknesses of 4 inches, 5 inches, 6
inches, and the like. For purposes of discussion, the particular
exemplary embodiment of FIGS. 1a, 1b, and 1c, will be described in
terms of a standard panel block having a length of 36 inches, a
height of 12 inches and a thickness of 6 inches.
[0045] A series of female dove-tail "interlock slots" 12 are formed
in the front face 14 of each block, as well as the back face 16,
the top surface 18, bottom surface 20, right hand 22 and left hand
24 edges. The interlock slots 12 may be formed by routing the slot
cutouts from a uniform 6 inch thick panel of EPS foam which has
been cut to the desired standard size (12.times.36, for example).
In a 36 inch long foam panel, it is contemplated that the interlock
slots are disposed approximately 12 inches apart on centers, with
the first slot on either face being provided about 6 inches from
either end. The interlock slots on the top and bottom edges, as
well as the two ends, are centered along the edge dimension.
[0046] In accordance with the invention, the interlock slots are
configured as female-type dove-tail joints and are shaped such that
the widest portion of the dove-tail (i.e., at the bottom of the
cutout) has a linear dimension approximately 1/3 that of the
thickness of the EPS panel into which it is routed or cut. In
effect, a female interlock slot would exhibit a maximum width, at
the bottom of the channel, of approximately 2 inches, were the EPS
panel to be a 6 inch thick panel. Necessarily, the interlock slot
will decrease in size as the panel thickness decreases.
[0047] Additionally, although the interlock slot is described as
exhibiting a width of about 1/3 the thickness of a panel, this is
not intended to represent a limitation on the configuration of a
slot. The size of a slot depends on the corresponding size of an
inserted "key", as will be described further below. Key and slot
widths may be allowed to vary as a function of the panel width and
as a function of the surface contact area as well as the amount of
bulk material defining the thickness of a key. A thicker key will
result in a greater degree of material resistance to lateral and
bending forces, with a correspondingly greater degree of joint
rigidity. Thus, interlock slot and key dimensions may be varied to
conform to structural design considerations and are not limited to
specific and fixed thicknesses, depths, and the like.
[0048] The slot aspect ratio is preferably less than 1:1, for
reasons which will be developed further below, but may, indeed, be
provided at a 1:1 aspect ratio without violating the scope and
spirit of the present invention. A suitable aspect ratio for
practice of the invention might be 0.8:1, with 0.8 referring to the
depth of the slot as a function of the width at the bottom of the
channel.
[0049] Similarly, the sides of the interlock slot are angled
inwardly at the mouth of the opening, so as to define a smaller
linear width dimension at the opening throat than at the bottom of
the slot. In particular, a suitable angle for each of the opening
sides is from about 6.degree. to about 7.5.degree.. Although these
angles appear to be most suitable for practice of the invention,
the actual values are not critical. A certain degree of variation
is allowable, so long as the system's structural integrity and
rigidity is not compromised, as will be explained in greater detail
below.
[0050] The particular form and location of the interlock slots 12
on a standardized block 10 allows for positioning and location of
other standardized blocks with respect to the first block. The
interlock slots define locations at which "interlock keys" are
inserted so as to tie multiple blocks together in a manner that
locks one block to another, provides structural rigidity to the
resulting "construct" in a manner heretofore unrealizable in EPS
foam materials.
[0051] Turning now to FIGS. 2a, 2b, and 2c, there is depicted a
male-type "interlock key" 30 which functions to join and lock
together two standardized building blocks (indicated at 10) in a
manner that insures structural integrity and rigidity of the
pieces. From the exemplary embodiment of FIG. 2a, it will be
understood that an "interlock key" 30 is configured as a male-type
dove-tail key that is shaped so as to slide into the female-type
dove-tail "interlock slot" 12 in secure fashion. The interlock key
30 is also formed from 2 pound EPS foam and is contemplated, in one
aspect, as comprising two superposed male-type dove-tale joints on
an elongate member. The interlock key is typically provided in
uniform lengths which equal the uniform length dimensions of a
standard-building panel such as described in the exemplary
embodiments of FIGS. 1a, 1b, and 1c. Where a building block is 36
inches long and 12 inches high, interlock keys will necessarily be
provided in both 36 inch and 12 inch lengths.
[0052] It should be understood that the interlock key 30 (more
correctly 1/2 of the interlock key) has depth corresponding to the
depth of an associated interlock slot 12. However, the width or
thickness of the engaging sides of the interlock key are
dimensioned to be approximately 0.005 inches oversized to the
corresponding dimension of the interlock slot. Suitable oversize
dimensions range from about 0.004 inches to about 0.007 inches.
Accordingly, as the interlock key member is slid into the interlock
slot, the sides of the key engage the sides of the slot in a
substantial friction fit and, because of the joint angle, serves to
pull the slot into tight engagement with the key. It could also be
said that the key 30 is pulled into tight engagement with the slot
12 by virtue of the dimensional oversize and the action of the
sidewall angles.
[0053] It should also be understood that the friction fit is
further dependant on the surface contact area between the slot and
key as well as the surface texture of the mating surfaces. Where
the respective surfaces are "rough cut" there will necessarily be a
greater surface friction resistance to both insertion and
extraction forces. Surface preparation can thus be varied in order
to give a range of friction fit characteristics, with smooth
surface preparation allowing for a smoother insertion and easier
extraction, but with a slightly reduced joint strength.
[0054] Insertion may be performed in a number of ways, with the key
30 being inserted into one slot 12 of one panel 10 and then another
panel having its interlock slot slid over the exposed surface of
the other half of the key 30 until it is positioned correctly.
Alternatively, two panels may be butted together at their
respective edges and the interlock key engaged to both interlock
slots simultaneously. In this case, the key dove-tail angle and
dimensional oversize functions to pull the two panels together
until their edge faces 32 are butted tightly together. The
compression forces along the panel edges give rigidity to two
panels joined together in this fashion making, in effect, a
composite piece having substantially the same rigidity and
integrity as a single panel. In order to ensure that adjoining
edges of butting panels are rigidly and securely compressed
together, it may be desirable to form the interlock key 30 such
that its bottom surface is approximately 0.005 inches from the
bottom channel surface of the interlock slot 12. This will increase
the "pulling" forces on each of the panels and further ensure that
maximum compression is developed along the respective edge faces
32.
[0055] Notably, panels are secured together through the friction
fit of a slightly oversized interlocked key 30 being disposed
within an interlock slot 12. Having an interlock key formed with
substantially the same depth as the interlock slot allows the
bottom faces of the key and the slot to engage, thereby increasing
contact surface area and maximizing bit friction. In this
particular case, structural rigidity is a function of how tightly
the key 30 is bound to the slot 12. Even though there is no gap
developed between the bottom of the key and the bottom of the slot,
sufficient compressive force is still developed between two panels
so as to lock the panels together into a rigid composite unit.
[0056] Although the exemplary embodiment of FIG. 2a depicts an
interlock key 30 as comprising two juxtaposed dove-tail key
members, it will be understood that interlock keys may be defined
as a single male-type dove-tail shape as depicted in the exemplary
embodiment of FIG. 2c. The juxtaposed shape of FIG. 2a is
particularly suitable when it is desired to marry two panels
together at their edges. The single key of FIG. 2c is particularly
suited for aligning and binding the edges of two panels together
when one panel is placed lengthwise atop another panel. In this
particular case, where each panel is 12 inches tall, the single
joint key might be 24 inches long and slid into each of the panels
end slots.
[0057] Further, and as will be described in greater detail below,
similar alignment and security may be had by inserting a single
joint key into the interlock slots disposed on the front and back
faces of two blocks if one block were to be disposed lengthwise
atop another. Thus, given the exemplary standardized panel of FIGS.
1, a single joint key would be inserted into each of the right hand
and left hand edge slots and the three slots on each panel's front
face, as well as the three slots on each panel's back face. For
additional rigidity and security, a dual joint key (FIG. 2a) may be
inserted into the "butterfly" openings defined by the lower panel's
top edge slot and the upper panel's bottom edge slot.
[0058] An additional embodiment of how an interlock key may be
formed is depicted in the additional exemplary embodiment of FIGS.
3a and 3b. In particular, an interlock key 34 may be provided with
a male-type dove-tail key 36 disposed at one end and a female-type
dove-tail interlock slot 38 disposed at the other end. Each of the
respective keys and slots are formed in a member manufactured of 2
pound EPS foam having substantially the same thickness dimension as
the panels which are desired to be joined. In this particular case,
one of the panels 40 is manufactured with a male-type dove-tail
interlock key formed along one edge and having the same oversize
characteristics as a separately provided interlock key. The male
key block may also be inserted directly into a standard block with
an interlock key as well as secured to a standard block through a
male/female interlock 34 as depicted in FIGS. 3a and 3b.
[0059] An additional configuration is depicted in FIGS. 4a and 4b,
where it might be found desirable to join together several building
panels at angles to one another. In the particular configuration of
FIG. 4a, an interlock member 40 is depicted as comprising a
female-type dove-tail interlock slot 42 on one side of a generally
pentagonal bulk shape, and two male-type dove-tail interlock keys
44 angled approximately 30.degree. apart from one another on the
bulk member's opposite side. As shown in FIG. 4b, a building panel
43 has a male-type interlock key disposed along one edge, with the
interlock member being slid over the interlock key of the panel 43.
Two standard panels 10 have interlock slots disposed along their
edges and the slots are engaged with the angled interlock keys 44
defined by the interlock member 40. In this manner, complex
building shapes may be defined that include panels that are
disposed at angle with respect to one another. This is particularly
suitable in the case of a child's playhouse where it is desirable
to provide a peaked roof for aesthetic purposes. Although,
hexagonal gazebos can be simply and easily constructed utilizing
this principal.
[0060] It should further be noted that although the interlock
member 40 of FIG. 4a is depicted with two male-type interlock keys
and one female-type interlock slot, it may just as easily have an
interlock key defined on the bottom face in place of the interlock
slot 42. Depending on the application, it might be desirable to
define an interlock slot in the pentagonal member 40 for purposes
of rigidity. If this is the case, the bottom surface of the
pentagonal member might also define a rectilinear cutout 46 into
which the interlock slot 42 is defined. The cutout 46 would serve
to define interior shoulders that receive the edge surface and edge
shoulders of a building panel 43 that is engaged to the interlock
slot 42. This particular configuration allows for maximum rigidity
against sideways deflection forces as might be the case where the
weight on one of the angularly displaced panels was greater than
the weight supported by the other angularly displaced panel.
[0061] The use of standard EPS foam building panels and standard
EPS foam interlock keys in constructing a structure will now be
discussed in connection with the exemplary embodiment depicted in
FIGS. 5a, 5b and 5c which show the top, plan and end view,
respectively, of a wall constructed in accordance with the present
invention. The wall might be a simple free standing wall or,
alternatively, it could form a wall portion of an easily assembled
tool shed, child's playhouse, backyard gazebo, pool house or any
other structure, housing or "construct" which does not have to meet
dwelling building codes.
[0062] In the exemplary embodiments of FIGS. 5a, 5b, and 5c,
building panels of three separate standardized sizes are depicted
as being joined together to form the wall. A 24 inch panel 50 will
be understood as comprising two interlock slots 12 disposed on each
of its front and back surfaces, as indicated in FIGS. 5a and 5b. A
36 inch long panel 52 is substantially similar to the exemplary
embodiment of FIGS. 1 and has three interlock slots disposed on
each of its front and back surfaces. A 48 inch panel 54 will
necessarily have four interlock slots disposed on each of its front
and back surfaces, in accordance with the general rule of slots
being disposed on 12 inch centers and 6 inches from the left and
right edge of each panel.
[0063] It will also be noted in the exemplary embodiment of FIGS.
5, that the panels are stacked, bottom edge to top edge, atop one
another such that their facial interlock slots line up vertically.
As shown in the exemplary embodiment of FIG. 5c, a dual interlock
key 30 (FIG. 2a) is inserted into the juxtaposed interlock slots of
the panel top and bottom edges. Likewise, and as shown in FIG. 5a,
the building panel's left and right edges are locked together by
sliding a dual interlock key (FIG. 2a) into the juxtaposed left and
right interlock slots. The various panels are now locked together
horizontally and vertically, but to maximize structural rigidity
and integrity of the completed structure, single sided interlock
keys 31 (FIG. 2b) are engaged to the vertically aligned facial
interlock slots of the various panels.
[0064] As shown in the exemplary embodiment of FIG. 5b, the single
sided keys 31 are provided in two separate lengths, one length
equal to the height of the panel (approximately 12 inches) while
another length is one half height of a panel (approximately 6
inches). This is to allow the foam material of the key to span the
butt joint between two blocks' top and bottom edges. The joint
between two consecutive single sided (or double sided) keys falls
in the center of a panel's material bulk, thereby minimizing
superposed joints and potential areas of weakness.
[0065] From the foregoing, it can be understood by those having
skill in the art, that a multi-angled interlock member (such as
member 40 of FIG. 4a) can be inserted in any one of the facially
disposed or end disposed slots so as to define the starting point
of an additional all structure or structures positioned at an angle
the first. Any number of panels can be fit together at any angle
with respect to one another and to any desired surface area, by
merely providing an appropriate interlock slot in an appropriate
location for receiving and interlock key once two shapes or
structures have their respective slots aligned.
[0066] A further exemplar of how the modular EPS foam construction
system and method in accordance with the invention might be
utilized to realize a complex structure is shown in the exemplary
embodiments of FIGS. 6, 7, 8 and 9. Specifically, the referenced
figures depict the construction of a hexagonal structure that is
sufficiently rigid to function as the structural support for a
stone or brick bench that might be constructed to surround a
favorite tree, for example or to surround a fire pit, or the
like.
[0067] Specifically, and with respect to the exemplary embodiments
of FIGS. 6a and 6b, the structure begins with a generally circular
piece of 2 pound EPS foam 60 which may or may not have a central
cut-out, depending on desired application. The circular base 60
includes socket cut-outs 62 into which vertical panel blocks 64 are
inserted. The cut-outs 62 may be formed slightly undersized to the
thickness dimension of the vertical panels 64, such that the
vertical panels friction fit into the cut-outs 62. Each of the
vertical support panels 64 terminates in a male-type dove-tail
interlock key 66 on its outward facing edge. The vertical supports
disposed about the circumference of the base 60.
[0068] Turning now to FIGS. 7a and 7b, an angled interlock member
40 (FIG. 4a) is secured to the outer edge of each of the vertical
support panels 64. Each angled member 40 receives the panel's
interlock key in an associated interlock slot and functions to
transform the single interlock key of each vertical panel 64 into
two angled interlock keys.
[0069] Suitably, two adjacent vertical panels may be locked
together by a linear EPS foam panel 66 having interlock slots cut
into one surface so as to join adjacent interlock keys. Once all of
the interlock keys join together by circumferentially disposed
exterior panels 66, the entire structure is now substantially
locked together and rigid, as depicted in the exemplary embodiment
of FIGS. 8a and 8b.
[0070] It will also be noted that the angled interlock members 40
are slightly longer than the height dimension of both the vertical
panels 64 and the exterior panels 66. The top edges of both the
vertical panels 64 and exterior panels 66 lie in the same plane,
with the top ends of the angled members 40 projecting beyond that
plane by a certain distance. This is to allow a set of cover panels
to be pressed over the surface of the underlying hexagonal support
with the extended portions of the angled interlock members 40
fitting within corresponding shaped receptacles cut into the
surface panels 68. It should further be noted that the receptacles
cut into the surface panels also incorporate interlock slots which
receive interlock key portions of the each of the angled interlock
members. This functions to provide compression forces to the
surface panels and to further lock the structure together and make
it rigid. The bottom surfaces of the surface panels 68 rest on the
top edges of the vertical support panels 64 and the top edges of
the exterior panels 66. When constructed in this fashion, the
resulting EPS foam article is capable of supporting the weight of
several persons, making it an ideal construct for outdoor, backyard
seating.
[0071] It should also be understood that once any of the
above-mentioned foam structures have been completed, they may be
finished with any form of surface texture that is desired. Faux
brick, rock, stucco or even stone or marble slabs can be affixed to
the exterior exposed surfaces of the completed foam article in
conventional fashion. Thus, even though constructed of and
structurally dependant on EPS foam, the article may be finished-off
to look as though it were made of stone. In the case where the
desired construct is a child's playhouse or a tool or pool shed,
the construct might be finished off with an exterior siding
applique to make it appear as though it were a frame-and-board
construction.
[0072] It should also be noted that although various interlock keys
have been described and depicted as made from 2 pound EPS foam,
other materials are also suitable for forming the keying function.
Interlock keys may be cut or milled from wood, for example, where
it is desired to provide a natural wood accent in an otherwise all
foam structure. In this particular case, a wooden key will also
allow for conventional fasteners to utilized where conventional
materials must be added to or incorporated into a foam construct.
Wooden keys allow for incorporation of screws and nails into the
construction, as well as adding a "natural" accent to a finished
product.
[0073] For certain other construction applications, it might be
desirable to provide the edge keys in metal, for example, if it is
desired to screw or bolt an EPS foam structure to a metal or wooden
wall. Similarly, a metal interlock key disposed along the bottom
edge of a foam structure can be milled with an internal "T" slot
such that bolt or pins might be extended from particular locations
along the length of the key so as to be countersunk into concrete,
for example.
[0074] Although the foregoing exemplary embodiments have been
characterized in terms of the exemplars of the figures, it will be
understood by those having skill in the art that building panels
need not be uniformly rectangular in shape nor need the interlock
slots (or interlock keys) be disposed in specific locations
thereon. Indeed, building panels might be curved so as to allow
construction of completely circular shapes or shapes with certain
amount of desired curvature such as a child's playground slide, for
example.
[0075] Building panels may be cut in custom shapes depending upon
the desired structure, such that one is not limited to the
particular dimensions imposed by 24, 36 or 48 inch panels. As
discussed, panels can be hexagonal, pentagonal, triangular or any
other shape as required. EPS foam is so simple to cut that no shape
can reasonably be excluded from contemplation of the present
invention. Indeed, all that is requires is that panels constructed
if EPS foam be rigidly locked and joined together by inserting an
interlock key into an interlock slot as discussed above.
[0076] Those having skill in the art will recognize that a
multitude of other shapes and configurations are equally suitable
for practice to the present invention. Accordingly, the invention
is not intended to be limited to the particular embodiments
discussed and depicted above, but rather defined by the scope of
the appended claims.
* * * * *